Display having a reflective polarizer

ABSTRACT

A multiple layer reflective polarizer  12  is described. This element is placed between and optical cavity  24  and an LCD module  16  to form an optical display. The reflective polarizer reflects some light into the optical cavity  24  where it is randomized and may ultimately emerge with the correct polarization to be transmitted out of the display.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.10/369,014, filed Feb. 19, 2003 now U.S. Pat. No. 7,038,745, nowallowed, which is a continuation of U.S. application Ser. No.09/451,346, filed Nov. 30, 1999 now U.S. Pat. No. 6,543,153, nowallowed, which is a continuation of U.S. application Ser. No.08/758,624, filed Nov. 27, 1996, issued as U.S. Pat. No. 6,025,897,which is a continuation of U.S. application Ser. No. 08/402,134, filedMar. 10, 1995, now abandoned, which is a continuation-in-part of U.S.application Ser. Nos. 08/359,592 and 08/359,436, both filed Dec. 20,1994, both now abandoned, which were continuations-in-part of U.S.application Ser. Nos. 08/172,596 and 08/171,239, filed Dec. 21, 1993,both now abandoned, all of which are incorporated hereim by reference.

TECHNICAL FIELD

The invention is an improved optical display.

BACKGROUND

Optical displays are widely used for lap-top computers, hand-heldcalculators, digital watches and the like. The familiar liquid crystal(LC) display is a common example of such an optical display. Theconventional LC display locates a liquid crystal and an electrode matrixbetween a pair of absorptive polarizers. In the LC display, portions ofthe liquid crystal have their optical state altered by the applicationof an electric field. This process generates the contrast necessary todisplay “pixels” of information in polarized light.

For this reason the traditional LC display includes a front polarizerand a rear polarizer. Typically, these polarizers use dichroic dyeswhich absorb light of one polarization orientation more strongly thanthe orthogonal polarization orientation. In general, the transmissionaxis of the front polarizer is “crossed” with the transmission axis ofthe rear polarizer. The crossing angle can vary from zero degrees toninety degrees. The liquid crystal, the front polarizer and rearpolarizer together make up an LCD assembly.

LC displays can be classified based upon the source of illumination.“Reflective” displays are illuminated by ambient light that enters thedisplay from the “front.” Typically a brushed aluminum reflector isplaced “behind” the LCD assembly. This reflective surface returns lightto the LCD assembly while preserving the polarization orientation of thelight incident on the reflective surface.

It is common to substitute a “backlight” assembly for the reflectivebrushed aluminum surface in applications where the intensity of theambient light is insufficient for viewing. The typical backlightassembly includes an optical cavity and a lamp or other structure thatgenerates light. Displays intended to be viewed under both ambient lightand backlit conditions are called “transflective.” One problem withtransflective displays is that the typical backlight is not as efficienta reflector as the traditional brushed aluminum surface. Also thebacklight randomizes the polarization of the light and further reducesthe amount of light available to illuminate the LC display.Consequently, the addition of the backlight to the LC display makes thedisplay less bright when viewed under ambient light.

Therefore, there is a need for a display which can develop adequatebrightness and contrast under both ambient and backlight illumination.

SUMMARY

The optical display of the present invention comprises three basicelements. The first element is a reflective polarizer. This reflectivepolarizer is located between a liquid crystal display (LCD) assembly andan optical cavity, which comprise the second and third elementsrespectively.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings depict representative and illustrative implementations ofthe invention. Identical reference numerals refer to identical structurethroughout the several figures, wherein:

FIG. 1 is a schematic cross section of an optical display according tothe invention;

FIG. 2 is a schematic cross section of an illustrative optical displayaccording to the invention;

FIG. 3 is a schematic cross section of an illustrative optical displayaccording to the invention;

FIG. 4 is an exaggerated cross sectional view of the reflectivepolarizer of the invention;

FIG. 5 shows the optical performance of the multilayer reflectivepolarizer of Example 2;

FIG. 6 is a schematic diagram of an optical display according to theinvention with brightness enhancement;

FIG. 7 is a diagram illustrating the operation of a brightness enhancer;

FIG. 8 is a graph illustrating the operation of a brightness enhancer;

FIG. 9 is a schematic cross section of an illustrative optical display;

FIG. 10 is a schematic cross section of an illustrative optical display;

FIG. 11 is a schematic cross section of an illustrative optical display;

FIG. 12 is a graph of test results;

FIG. 13 is a schematic cross section of an illustrative optical display;

FIG. 14 is a schematic cross section of a brightness enhanced reflectivepolarizer;

FIG. 15 shows a two layer stack of films forming a single interface.

FIGS. 16 and 17 show reflectivity versus angle curves for a uniaxialbirefringent system in a medium of index 1.60.

FIG. 18 shows reflectivity versus angle curves for a uniaxialbirefringent system in a medium of index 1.0.

FIGS. 19, 20 and 21 show various relationships between in-plane indicesand z-index for a uniaxial birefringent system.

FIG. 22 shows off axis reflectivity versus wavelength for two differentbiaxial birefringent systems.

FIG. 23 shows the effect of introducing a y-index difference in abiaxial birefringent film with a large z-index difference.

FIG. 24 shows the effect of introducing a y-index difference in abiaxial birefringent film with a small z-index difference.

FIG. 25 shows a contour plot summarizing the information from FIGS. 18and 19;

FIGS. 26-31 show optical performance of multilayer mirrors given inExamples 3-6;

FIGS. 32-36 show optical performance of multilayer polarizers given inExamples 7-11;

FIG. 37 shows optical performance of the multilayer mirror given inExample 12;

FIG. 38 shows optical performance of the AR coated polarizer given inExample 13;

FIG. 39 shows optical performance of the polarizer given in Example 14;and

FIGS. 40A-40C show optical performance of multilayer polarizers given inExample 15.

DETAILED DESCRIPTION

FIG. 1 is a schematic diagram of an illustrative optical display 10 thatincludes three principle components. These include the polarizingdisplay module shown as LCD assembly 16, a reflective polarizer 12, andan optical cavity 24.

The LCD assembly 16 shown in this figure is illuminated by polarizedlight provided by the reflective polarizer 12 and the optical cavity 24.

Ambient light incident on the display 10, depicted by ray 60 traversesthe LCD module 16, the reflective polarizer 12 and strikes the diffusereflective surface 37 of the optical cavity 24. Ray 62 depicts thislight as it is reflected by the diffusely reflective surface 37 towardthe reflective polarizer 12.

Light originating from within the optical cavity 24 is depicted by ray64. This light is also directed toward the reflective polarizer 12 andpasses through the diffusely reflective surface 37. Both ray 62 and ray64 have light exhibiting both polarization states (a,b).

FIG. 2 shows a schematic optical display 11 illustrated with a threelayer LCD assembly 15 that includes a front polarizer 18, a liquidcrystal 20 and a rear polarizer 23. In this embodiment the opticalcavity 24 is an edge lit backlight which includes a lamp 30 in areflective lamp housing 32. Light from the lamp 30 is coupled to thelight guide 34 where it propagates until it encounters a diffusereflective structure such as spot 36. This discontinuous array of spotsis arranged to extract lamp light and direct it toward the LCD module15. Ambient light entering the optical cavity 24 may strike a spot or itmay escape from the light guide through the interstitial areas betweenspots. The diffusely reflective layer 39 is positioned below the lightguide 34 to intercept and reflect such rays. In general, all the raysthat emerge from the optical cavity 24 are illustrated by ray bundle 38.This ray bundle is incident on the reflective polarizer 12 whichtransmits light having a first polarization orientation referred to as“(a)” and effectively reflects light having the orthogonal polarizationorientation (b). Consequently, a certain amount of light, depicted byray bundle 42, will be transmitted by the reflective polarizer 12 whilea substantial amount of the remaining light will be reflected asindicated by ray bundle 40. The preferred reflective polarizer materialis highly efficient and the total losses due to absorption within thereflective polarizer 12 are very low (on the order of 1 percent). Thislost light is depicted by ray bundle 44. The light having polarizationstate (b) reflected by the reflective polarizer 12 reenters the opticalcavity 24 where it strikes the diffusely reflective structures such asspot 36 or the diffusely reflective layer 39. The diffusely reflectivesurfaces serve to randomize the polarization state of the lightreflected by the optical cavity 24. This recirculation and randomizationprocess is depicted as path 48. The optical cavity 24 is not a perfectreflector and the light losses in the cavity due to scattering andabsorption are depicted by ray bundle 46. These losses are also low (onthe order of 20 percent). The multiple recirculations effected by thecombination of the optical cavity 24 and the reflective polarizer 12form an efficient mechanism for converting light from state (b) to state(a) for ultimate transmission to the viewer.

The effectiveness of this process relies on the low absorption exhibitedby the reflective polarizer disclosed herein and the high reflectivityand randomizing properties exhibited by many diffusely reflectivesurfaces. In FIG. 2 both the discontinuous layer depicted by spot 36 andthe diffusely reflective continuous layer 39 may be formed of a titaniumoxide pigmented material. It should be appreciated that a diffusereflective surface 37 (shown in FIG. 1) can be formed of transparentsurface textured polycarbonate. This material could be placed above thelight guide 34 to randomize incident light in the configuration shown inFIG. 2. The specific and optimal configuration will depend on theparticular application for the completed optical display.

In general, the gain of the system is dependent on the efficiency ofboth the reflective polarizer body 12 and the optical cavity 24.Performance is maximized with a highly reflective optical cavity 24consistent with the requirement of randomization of the polarization ofincident light, and a very low loss reflective polarizer 12.

FIG. 3 shows a schematic optical display 14 illustrated with a two layerLCD assembly 17 that includes a front polarizer 18 and a liquid crystal20. In this embodiment the optical cavity 24 includes anelectroluminescent panel 21. The traditional electroluminescent panel 21is coated with a phosphor material 19 that generates light when struckby electrons and that is also diffusely reflective when struck byincident light. Usually, electroluminescent displays are “grainy”because of the variations in efficiencies associated with the phosphorcoating. However, light returned by the reflective polarizer 12 has atendency to “homogenize” the light emissions and improve overalluniformity of illumination exhibited by the optical display 14. In theillustrative optical display 14 the LCD assembly 17 lacks a rearpolarizer. In this optical display 14 the reflective polarizer 12performs the function normally associated with the rear polarizer 23shown in optical display 11 in FIG. 2.

FIG. 4 is a schematic perspective diagram of a segment of the reflectivepolarizer 12. The figure includes a coordinate system 13 that defines X,Y and Z directions that are referred to in the description of thereflective polarizer 12.

The illustrative reflective polarizer 12 is made of alternating layers(ABABA . . . ) of two different polymeric materials. These are referredto as material “(A)” and material “(B)” throughout the drawings anddescription. The two materials are extruded together and the resultingmultiple layer (ABABA . . . ) material is stretched (5:1) along one axis(X), and is not stretched appreciably (1:1) along the other axis (Y).The X axis is referred to as the “stretched” direction while the Y axisis referred to as the “transverse” direction.

The (B) material has a nominal index of refraction (n=1.64 for example)which is not substantially altered by the stretching process.

The (A) material has the property of having the index of refractionaltered by the stretching process. For example, a uniaxially stretchedsheet of the (A) material will have one index of refraction (n=1.88 forexample) associated with the stretched direction and a different indexof refraction (n=1.64 for example) associated with the transversedirection. By way of definition, the index of refraction associated withan in-plane axis (an axis parallel to the surface of the film) is theeffective index of refraction for plane-polarized incident light whoseplane of polarization is parallel to that axis.

Thus, after stretching the multiple layer stack (ABABA . . . ) ofmaterial shows a large refractive index difference between layers (deltan=1.88−1.64=0.24) associated with the stretched direction. While in thetransverse direction, the associated indices of refraction betweenlayers are essentially the same (delta n=1.64−1.64=0.0). These opticalcharacteristics cause the multiple layer laminate to act as a reflectingpolarizer that will transmit the polarization component of the incidentlight that is correctly oriented with respect to the axis 22. This axisis defined as the transmission axis 22 and is shown in FIG. 4. The lightwhich emerges from the reflective polarizer 12 is referred to as havinga first polarization orientation (a).

The light that does not pass through the reflective polarizer 12 has apolarization orientation (b) that differs from the first orientation(a). Light exhibiting this polarization orientation (b) will encounterthe index differences which result in reflection of this light. Thisdefines a so-called “extinction” axis shown as axis 25 in FIG. 4. Inthis fashion the reflective polarizer 12 transmits light having aselected polarization (a) and reflects light having the polarization(b).

Although the reflective polarizer 12 has been discussed with anexemplary multiple layer construction which includes alternating layersof only two materials it should be understood that the reflectivepolarizer 12 may take a number of forms. For example, additional typesof layers may be included into the multiple layer construction. Also ina limiting case, the reflective polarizer may include a single pair oflayers (AB) one of which is stretched. Furthermore, a dichroic polarizercould be bonded directly to reflective polarizer 12.

Another important property of the optical cavity 24 is the fact thatpolarization randomization process associated with the cavity will alsoalter the direction of the incident light. In general, a significantamount of light exits the optical cavity off-axis. Consequently, thepath of such light in the reflective polarizer is longer than the pathlength for near normal light. This effect must be addressed to optimizethe optical performance of the system. The reflective polarizer body 12described in the example is capable of broadband transmission into thelonger wavelengths which is desirable to accommodate off-axis rays. FIG.5 shows trace 31 which indicates a transmissivity of over 80 percentover a wide range of wavelengths. Trace 33 shows efficient broadbandreflectively over a large portion of the visible spectrum. The optimalreflectivity trace would extend into the infrared and extend fromapproximately 400 nm to approximately 800 nm.

In another embodiment, the apparent brightness of the display may beincreased by the use of a brightness enhancement film. FIG. 6 shows anoptical display 164 which has three primary components. These are theoptical display module 142, the brightness enhanced reflective polarizer110 and the optical cavity 140. Typically the complete optical display164 will be planar and rectangular in plan view as seen by observer 146and will be relatively thin in cross section with the three primarycomponents in close proximity to each other.

In use, the display module 142 is illuminated by light processed by thebrightness enhanced reflective polarizer 110 and the optical cavity 140.Together these two components direct polarized light into a viewing zone136 shown schematically as an angle. This light is directed through thedisplay module 142 toward the observer 146. The display module 142 willtypically display information as pixels. Polarized light transmissionthrough a pixel is modulated by electrical control of the birefringenceof the liquid crystal material. This modulates the polarization state ofthe light, affecting its relative absorption by a second polarizer layerthat forms a part of the display module 142.

There are two sources for illumination shown in the figure. The first isambient light depicted by ray 162. This light passes through the displaymodule 142 and brightness enhanced reflective polarizer 110 and isincident on the optical cavity 140. The optical cavity reflects thislight as indicated by ray 165. The second source of light may begenerated within the optical cavity itself as depicted by ray 163. Ifthe optical cavity 140 is a backlight then the principal source ofillumination originates within the optical cavity 140 and the opticaldisplay is referred to as “backlit.” If the principal source ofillumination is ambient light represented by ray 162 and ray 165 thenthe optical display is called “reflective” or “passive.” If the displayis to be viewed under both ambient and cavity generated light thedisplay is called “transflective.” The present invention is useful ineach of these display types.

Regardless of the origin of the light, the brightness enhancedreflective polarizer 110 and the optical cavity 140 cooperate togetherto “recirculate” light so that the maximum amount of light is properlypolarized and confined to the viewing zone 136.

In general, the brightness enhanced reflective polarizer 110 includestwo elements. The first is a reflective polarizer body 116 thattransmits light of a particular polarization to the viewing zone 136.The second element is the optically structured layer 113 that definesthe boundaries of the viewing zone 136.

The optical cavity 140 serves several functions but with respect to itsinteraction with the brightness enhanced reflective polarizer 110, theimportant parameters are a high reflectance value with respect toincident light and the ability of the optical cavity 40 to alter boththe direction and the polarization of the incident light. Conventionaloptical cavities meet these requirements.

For any optical system, the sum of the reflectivity, losses andtransmissivity must equal 100 percent of the light. Absorbance can be amajor source of such losses. In the present invention the brightnessenhanced reflective polarizer 110 has a very low absorbance and highreflectivity to certain light. Consequently light that is not passeddirectly into the viewing zone 136 is efficiently transferred to theoptical cavity 140 where it is altered and may emerge from the cavitywith the proper attributes to contribute to the light in the viewingzone 136.

In the context of the optical display 164 the overall gain of the systemdepends on the product of the reflectivity of the optical cavity 140 andthe reflectivity of the brightness enhanced reflective polarizer 110.The invention is most effective when used with a low absorption opticalcavity that has a high reflectivity rear surface consistent with itsability to alter the direction and polarization state of the incidentlight from the brightness enhanced reflective polarizer 110. For thesepurposes it should be noted that the optical cavity could be filled witha transparent dielectric material such as an acrylic.

Although the preferred structured surface 112 functions as a geometricoptic it is well known that diffractive or holographic optical elementsmay be designed to effectively mimic the light directing qualitiesexhibited by geometric optics. Therefore the term structured surface 112should be understood to describe both geometric and diffractive opticalsystems that confine light to a relatively narrow viewing zone 136.

FIG. 7 is an enlargement of structured surface material that will act asa brightness enhancer in the present invention. As described previously,structured surface material 218 has a smooth side 220 and a structuredside 222. Structured side 222, in the preferred embodiment, includes aplurality of triangular prisms. In the preferred embodiment, such prismsare right isosceles prisms, although prisms having peak angles in therange of 70 degrees to 110 degrees will work with varying degrees ofeffectiveness with the invention. Structured surface material 218 may beof any transparent material having an index of refraction greater thanthat of air, but, in general, the materials with higher indices ofrefraction will produce better results. Polycarbonate, which has anindex of refraction of 1.586, has proven to work very effectively. Forpurposes of description of the invention, the prisms on structuredsurface 222 will be assumed to have included angles of 90 degrees andstructured surface material 218 will be assumed to be of polycarbonate.Alternatively other structured surface materials may be used. Symmetriccube corner sheeting has been shown to produce excellent results.

FIG. 8 illustrates the operation of structured surface material 218.FIG. 8 is a graph having two axes 226 and 228. These axes represent theangle that a light ray makes to a normal to smooth surface 220.Specifically, axis 226 represents the angle that the light ray makeswhen the direction of the light ray is projected into a plane parallelto the linear extent of the structures on structured surface 222.Similarly axis 228 represents the angle that the light ray makes to anormal to smooth surface 220 when the direction of the light ray isprojected into a plane perpendicular to the linear extent of thestructures on structured surface 222. Thus a light ray strikingperpendicular to smooth surface 220 would be represented by the origin,labeled 0 degrees, of the graph of FIG. 8. As may be seen, FIG. 8 isdivided into regions 230, 232, and 234. Light striking at angles thatfall within region 230 will enter structured surface material 218 but betotally internally reflected by structured surface 222 so that they passthrough smooth surface 220 a second time and reenter the optical cavity.Light rays striking smooth surface 220 at an angle such that they fallin region 232 or 234 will be transmitted but refracted to a differentangle with respect to the normal. As may be seen from FIG. 8, whichrepresents the performance of polycarbonate, any light ray strikingsmooth surface 220 at an angle of less than 9.4 degrees to the normal,will be reflected.

Returning to FIG. 7, four exemplary light rays are shown. The first,light ray 236, approaches smooth surface 220 at a grazing angle, i.e.,an angle to the normal approaching 90 degrees. If light ray 236 makes anangle of 89.9 degrees to the normal to surface 220 when it strikesstructured surface material 218, it will be refracted such that it makesan angle of 39.1 degrees to the normal as it travels through structuredsurface material 218. Upon reaching structured surface 222, it will berefracted again. Because of the structures on structured surface 222, itwill be refracted so that again it will make a smaller angle to thenormal to structured surface 220. In the example it will make an angleof 35.6 degrees.

Light ray 238 approaches smooth surface 220 at an angle much closer tothe cut off angle. It also is refracted as it passes through smoothsurface 220, but to a lesser extent. If light ray 238 approaches smoothsurface 220 at an angle of 10 degrees to the normal to smooth surface220, it will emerge from structured surface 222 at an angle of 37.7degrees to the normal to smooth surface 220 but on the opposite side ofthat normal.

Light ray 240 approaches at an angle less than the cut off angle and istotally internally reflected twice by structured surface 222 andreturned to the interior of the optical cavity.

Finally, light ray 242 approaches smooth surface 220 at an angle similarto that of light ray 238, but in a location such that it is totallyinternally reflected by one side of a prism on structured surface 222but not by the second side. As a result it emerges at a large angle tothe normal to smooth surface 220. Because such a reflection only occursto a light ray that is travelling in a direction that forms a highincidence angle to the side it strikes, the prisms provide a very smallcross section to such rays. In addition many of those rays will reenterthe next prism and be returned into display 210.

A fifth class of light ray is not shown in FIG. 7. This is the set oflight rays that are reflected by smooth surface 220 and do not enterstructured surface material 218. Such light rays simply join the othersthat are reflected back into the optical cavity. As may be seen fromthis discussion, light that, absent structured surface material 218,would have emerged from the display at a high angle to the axis of thedisplay, where the axis of the display is taken to be the normal tosmooth surface 220, is redirected into a direction closer to that axis.A small amount of light will be directed out at a large angle to theaxis. Thus, we may say that light that enters structured surfacematerial 218 through smooth surface 220 with an angle of incidencegreater than a predetermined angle is directed into an output wedge thatis narrower than the input wedge and the majority of the light thatenters structured surface material 18 through smooth surface 220 at anangle of incidence of less than that predetermined angle will bereflected back into the optical cavity.

The light that is reflected back into the optical cavity will strike thediffuse reflector. The reflected light will travel back to structuredsurface material 218, in general making a different angle than it madethe first time. The process is then repeated so that more of the lightis redirected into the smaller wedge. The key aspect of the invention isthat structured surface material 218 must be capable of reflecting lightstriking it in a first predetermined group of angles and passing, butrefracting, light striking it in a second predetermined group of angleswherein the angles in the second group of angles are greater than thosein the first group of angles and wherein the light in the second groupof angles is refracted into an output wedge that is narrower than itsinput wedge. In this description the first and second groups of anglesare relative to an axis of the display perpendicular to the displaysurface, i.e. the liquid crystal.

FIG. 9 shows a portion of the schematic optical display 164 without thebrightness enhanced reflective polarizer 110 material to permit acomparison of performance without the brightness enhanced reflectivepolarizer 110. In general, the light emerging from a unit area of theoptical cavity 140 depicted by ray bundle 148 will be randomly polarizedand have optical states (a), (b), (c), and (d) present. Approximatelyhalf of this light, light of states (b) and (d), are absorbed by thedichroic absorptive polarizer 150 that forms a part of the displaymodule 142. The remainder of the light, states (a) and (c), are passedthrough the dichroic absorptive polarizer 150. The light emerging fromthe display module 142, depicted by ray bundle 152, thus contains lightof states (a) and (c). Although the light of state (a) is directedtoward the observer 146, the light of state (c) is not. The remainder ofthe light having states (b) and (d) will be absorbed by the dichroicabsorptive polarizer 150. Thus, only approximately one quarter of thelight provided by optical cavity 140 actually contributes to thebrightness of the display as viewed by observer 146.

The brightness enhanced reflective polarizer operates to make moreefficient use of the light made available by optical cavity 140. If thesame unit amount of light, depicted by ray bundle 154, is directed tothe brightness enhanced reflective polarizer 110, approximately aquarter of the light (light of state (a)) will pass through thebrightness enhanced reflective polarizer 110 on the first pass. Thislight will have the correct polarization to match the transmission axisof the dichroic absorptive polarizer 150, and is depicted as ray bundle161. However the remaining light having states (b), (c), and (d) will bereflected back into the optical cavity by the brightness enhancedreflective polarizer 110. Some portion of this light will be randomizedin terms of direction and polarization to state (a) by the opticalcavity 140. Thus, this light will emerge from the optical cavity withstates (a), (b), (c), and (d) as indicted by ray bundle 157. Therecirculated light of state (a) will then be added to the originallytransmitted light as depicted by ray bundle 160. Thus, the total amountof light depicted by ray bundle 160 and ray bundle 161 is increased by“recirculation.” Because only light of the correct polarization to matchthe transmission axis of the dichroic absorptive polarizer 150 (state(a)) is passed through the brightness enhanced reflective polarizer 110,much more of the light emitted from the display, depicted by ray bundle63, is directed toward the observer 146. In addition, because light ofstates (b) and (d) is reflected by the brightness enhanced reflectivepolarizer 110, very little is absorbed by the dichroic absorptivepolarizer 150. The result is a display in which the amount of lightemerging from the display, depicted by ray bundle 163, may be 70 percentbrighter than the amount of light indicated by ray bundle 152.

FIG. 10 shows an optical display 170. The optical display module 142includes a liquid crystal matrix 147 placed between a front polarizer149 and a rear polarizer 150. In this embodiment the opticallystructured layer 113 is separated from the reflective polarizer body 116by gap 171. The gap 171 introduces reflections for state (a) light rayswhich are not desirable. In the display 170 the optical cavity 140 is abacklight which includes a lamp 172 within a lamp reflector 173. Lightfrom the lamp 172 enters the light guide 174 and travels until itstrikes a diffuse reflective surface such as spot 176. Although adiscontinuous array of such spots is required to effectively extractlight from the light guide 174, the intermittent surface may not besufficient to fully recirculate light. Therefore it is preferred toplace a continuous diffuse reflective surface 175 below thediscontinuous surface to aid in the recirculation process.

FIG. 11 shows an optical display 179 where the optically structuredlayer 113 and structured surface 112 is a separate element proximate butnot directly applied to the reflective polarizer body 116. Togetherthese two components along with the gap 181 make up the brightnessenhanced reflective polarizer 110. In use, the optical cavity 140 willprovide light for the display and will also act to reorient thepolarization and direction of light returned from the brightnessenhanced reflective polarizer 110. The optical cavity 140 includes anelectroluminescent panel 139 having a phosphor coating which acts as adiffuse reflective surface 137. One difference between this embodimentof the brightness enhanced reflective polarizer 110 and that of FIG. 10is that light approaching the structured surface 112 at an angle greaterthan the critical angle 134 is returned to the optical cavity by totalinternal reflection regardless of its state of polarization. Anotherdifference is that the light transmitted by optically structured layer113 passes through the reflective polarizer body 116 at near normalangles. A further difference relates to the presence of a frontpolarizer 149 and the absence of a rear polarizer in the display module143. In embodiments where the backlight is the dominant source of light,adequate contrast can be achieved without the use of an absorptivepolarizer juxtaposed next to the brightness enhanced reflectivepolarizer.

FIG. 12 shows test results of a sample of brightness enhanced reflectivepolarizer material taken with a standard electroluminescent backlight.The electroluminescent backlight met the requirements set forth abovefor the optical cavity in terms of randomizing the direction and thepolarization orientation of incident light. To provide a basis forcomparison, curve 162 shows light transmission for a display having onlya dichroic polarizer alone without a brightness enhancement reflectivepolarizer body. Curve 164 represents the intensity of light versus theangular distribution of light for the Y-Z plane of a display whichincludes a brightness enhanced reflective polarizer body in aconfiguration with the reflective polarizer body and structured surfaceas proximate layers, such as that shown and described above with respectto FIG. 12. Curve 164 shows that an on-axis brightness increase of aboutsixty percent as compared to the dichroic polarizer alone is achieved.Also, a brightness decrease of about 50 percent is observed at 60degrees off-axis.

In yet another example, using a standard backlight, a brightnessincrease of 100 percent over a dichroic polarizer alone was measuredalong the display normal to the viewing surface with a brightnessenhanced reflective polarizer with the reflective polarizer body andstructured surface as proximate layers such as shown and described abovewith respect to FIG. 11. The reflective polarizer alone yielded abrightness increase of 30 percent, while the structured surface aloneyielded a brightness increase of 70 percent, thus resulting in a totalbrightness increase of 100 percent for on-axis viewing.

The difference in brightness increase between these two examples islargely due to the different optical cavities used. The curve of FIG. 12was taken with an electroluminescent backlight, while the latter examplewas taken with a standard backlight. The reflectance and losses of eachtype of optical cavity effects the overall brightness increase that canbe achieved.

Two dimensional control of the rays exiting the brightness enhancedreflective polarizer body can be achieved using the alternate preferreddisplay configuration 192 shown in FIG. 13. There, two opticallystructured layers 113 and 182, each having a structured surface 112 and184, respectively, are proximate to each other and to a reflectivepolarizer body 116. These three elements comprise the brightnessenhanced reflective polarizer body 110. Although in FIG. 13 the twooptically structured layers are shown below the reflective polarizerbody 116, it shall be understood that the reflective polarizer body 116could also be placed between or below the optically structured layers112 and 182 without departing from the scope of the present invention.Two dimensional control is achieved by crossing the axes of orientationof the structured surfaces 112 and 184. The axes may be oriented at 90degrees or at some other angle greater than 90 degrees depending uponthe display application and associated polarization requirements.

In operation, the first optically structured layer results in a viewingzone of approximately 70 degrees in the Y, Z plane and 110 degrees inthe X, Z plane. The light exiting the first optically structured layer182 then becomes the source for the second optically structured layer113, whose structured surface 112 has a different axes of orientationthan does the structured surface 184 of optically structured layer 182.If the axes of the two optically structured layers 113 and 184 areoriented at 90 degrees, for example, optically structured layer 182operates on the light within the 110 degree angle of the X, Z plane andcompresses the viewing angle in the X, Z plane to a narrower field ofsomething less than 70 degrees, thereby further increasing brightness.

FIG. 14 is a schematic and perspective view of the brightness enhancedreflective polarizer 110 shown in isolation. The figure is not drawn toscale to facilitate description of the structure of the invention. FIG.14 among others include a coordinate system 118 that defines X, Y and Zdirections that are referred to in the description of the invention.

As seen in FIG. 14 the brightness enhanced reflective polarizer 110includes an optically structured layer 113 that has a structured surface112. In FIG. 14 this optically structured layer 113 is replicated on apolymer layer cast onto the reflective polarizer body 116, resulting ina preferred unitary structure. A unitary structure such as the one shownin FIG. 14 may be formed by various known techniques of attaching twofilms, such as heat lamination or casting and curing the structuredsurface material on the reflective polarizer where the reflectivepolarizer acts as the substrate in a process such as is described inU.S. Pat. No. 5,175,030. For purposes hereof, the statement that thereflective polarizer and the brightness enhancer are unitary shall beunderstood to mean that they are bonded to one another.

The preferred and illustrative structured surface 112 shown in FIG. 14,is an array of prisms, typified by prism 114. Each prism has an apexridge that extends in the X direction. In the Y, Z plane each prism 114has a cross section that is an isosceles triangle, with a preferredprism apex angle 120 of ninety degrees. Although an array of prisms ispreferred, the specific prism geometry and apex angles 120 may bealtered to meet the specific requirements of the application. An arrayof prisms as shown in FIG. 14 is especially useful where it is desirableto confine the light exiting the optical display to a relatively narrowviewing zone 136 shown on FIG. 6. However, where other viewing anglesare desired, the optically structured layer 113 may take other forms.Although the preferred structured surface 112 functions as a geometricoptic it is well known that diffractive or holographic optical elementsmay be designed to effectively mimic the light directing qualitiesexhibited by geometric optics. Therefore the term structured surface 112should be understood to describe both geometric and diffractive opticalsystems which confine light to a relatively narrow viewing zone 136(FIG. 6). Due to the inherent polarizing nature of an array of prisms,generally speaking, optimum performance is achieved when the axes of theprisms run parallel to the direction in which the reflective polarizerwas stretched.

Optical Behavior and Design Considerations of Multilayer Stacks

The optical behavior of a multilayer stack 10 such as that shown abovein FIG. 4 will now be described in more general terms.

The optical properties and design considerations of multilayer stacksdescribed below allow the construction of multilayer stacks for whichthe Brewster angle (the angle at which reflectance goes to zero) is verylarge or is nonexistant. This allows for the construction of multilayermirrors and polarizers whose reflectivity for p polarized light decreaseslowly with angle of incidence, are independent of angle of incidence,or increase with angle of incidence away from the normal. As a result,multilayer stacks having high reflectivity for both s and p polarizedlight over a wide bandwidth, and over a wide range of angles can beachieved.

The average transmission at normal incidence for a multilayer stack,(for light polarized in the plane of the extinction axis in the case ofpolarizers, or for both polarizations in the case of mirrors), isdesirably less than 50% (reflectivity of 0.5) over the intendedbandwidth. (It shall be understood that for the purposes of the presentapplication, all transmission or reflection values given include frontand back surface reflections). Other multilayer stacks exhibit loweraverage transmission and/or a larger intended bandwidth, and/or over alarger range of angles from the normal. If the intended bandwidth is tobe centered around one color only, such as red, green or blue, each ofwhich has an effective bandwidth of about 100 nm each, a multilayerstack with an average transmission of less than 50% is desirable. Amultilayer stack having an average transmission of less than 10% over abandwidth of 100 nm is also preferred. Other exemplary preferredmutlilayer stacks have an average transmission of less than 30% over abandwidth of 200 nm. Yet another preferred multilayer stack exhibits anaverage transmission of less than 10% over the bandwidth of the visiblespectrum (400-700 nm). Most preferred is a multilayer stack thatexhibits an average transmission of less than 10% over a bandwidth of380 to 740 nm. The extended bandwidth is useful even in visible lightapplications in order to accommodate spectral shifts with angle, andvariations in the multilayer stack and overall film caliper.

The multilayer stack 10 can include tens, hundreds or thousands oflayers, and each layer can be made from any of a number of differentmaterials. The characteristics which determine the choice of materialsfor a particular stack depend upon the desired optical performance ofthe stack.

The stack can contain as many materials as there are layers in thestack. For ease of manufacture, preferred optical thin film stackscontain only a few different materials. For purposes of illustration,the present discussion will describe multilayer stacks including twomaterials.

The boundaries between the materials, or chemically identical materialswith different physical properties, can be abrupt or gradual. Except forsome simple cases with analytical solutions, analysis of the latter typeof stratified media with continuously varying index is usually treatedas a much larger number of thinner uniform layers having abruptboundaries but with only a small change in properties between adjacentlayers.

Several parameters may affect the maximum reflectivity achievable in anymultilayer stack. These include basic stack design, optical absorption,layer thickness control and the relationship between indices ofrefraction of the layers in the stack. For high reflectivity and/orsharp bandedges, the basic stack design should incorporate opticalinterference effects using standard thin film optics design. Thistypically involves using optically thin layers, meaning layers having anoptical thickness in the range of 0.1 to 1.0 times the wavelength ofinterest. The basic building blocks for high reflectivity multilayerfilms are low/high index pairs of film layers, wherein each low/highindex pair of layers has a combined optical thickness of ½ the centerwavelength of the band it is designed to reflect. Stacks of such filmsare commonly referred to as quarterwave stacks.

To minimize optical absorption, the preferred multilayer stack ensuresthat wavelengths that would be most strongly absorbed by the stack arethe first wavelengths reflected by the stack. For most clear opticalmaterials, including most polymers, absorption increases toward the blueend of the visible spectrum. Thus, it is preferred to tune themultilayer stack such that the “blue” layers are on the incident side ofthe multilayer stack.

A multilayer construction of alternative low and high index thick films,often referred to as a “pile of plates”, has no tuned wavelengths norbandwidth constraints, and no wavelength is selectively reflected at anyparticular layer in the stack. With such a construction, the bluereflectivity suffers due to higher penetration into the stack, resultingin higher absorption than for the preferred quarterwave stack design.Arbitrarily increasing the number of layers in a “pile of plates” willnot always give high reflectivity, even with zero absorption. Also,arbitrarily increasing the number of layers in any stack may not givethe desired reflectivity, due to the increased absorption which wouldoccur.

The relationships between the indices of refraction in each film layerto each other and to those of the other layers in the film stackdetermine the reflectance behavior of the multilayer stack at any angleof incidence, from any azimuthal direction. Assuming that all layers ofthe same material have the same indices, then a single interface of atwo component quarterwave stack can be analyzed to understand thebehavior of the entire stack as a function of angle.

For simplicity of discussion, therefore, the optical behavior of asingle interface will be described. It shall be understood, however,that an actual multilayer stack according to the principles describedherein could be made of tens, hundreds or thousands of layers. Todescribe the optical behavior of a single interface, such as the oneshown in FIG. 15, the reflectivity as a function of angle of incidencefor s and p polarized light for a plane of incidence including thez-axis and one in-plane optic axis will be plotted.

FIG. 15 shows two material film layers forming a single interface, withboth immersed in an isotropic medium of index no. For simplicity ofillustration, the present discussion will be directed toward anorthogonal multilayer birefringent system with the optical axes of thetwo materials aligned, and with one optic axis (z) perpendicular to thefilm plane, and the other optic axes along the x and y axis. It shall beunderstood, however, that the optic axes need not be orthogonal, andthat nonorthogonal systems are well within the spirit and scope of thepresent invention. It shall be further understood that the optic axesalso need not be aligned with the film axes to fall within the intendedscope of the present invention.

The reflectivity of a dielectric interface varies as a function of angleof incidence, and for isotropic materials, is different for p and spolarized light. The reflectivity minimum for p polarized light is dueto the so called Brewster effect, and the angle at which the reflectancegoes to zero is referred to as Brewster's angle.

The reflectance behavior of any film stack, at any angle of incidence,is determined by the dielectric tensors of all films involved. A generaltheoretical treatment of this topic is given in the text by R. M. A.Azzam and N. M. Bashara, “Ellipsometry and Polarized Light”, publishedby North-Holland, 1987.

The reflectivity for a single interface of a system is calculated bysquaring the absolute value of the reflection coefficients for p and spolarized light, given by equations 1 and 2, respectively. Equations 1and 2 are valid for uniaxial orthogonal systems, with the axes of thetwo components aligned.rpp=n2z*n2o√(n1z2−no2 sin 2θ)−n1z*n1o√(n2z 2−no2 sin2θ)n2z*n2o√(n1z2−no2 sin 2θ)+n1z*n1o√(n2z2−no2 sin 2θ)  1)rss=√(n1o2−no2 sin 2θ)−√(n2o2−no2 sin 2θ)√(n1o2−no2 sin 2θ)+√(n2o2−no2sin 2θ)  2)where θ is measured in the isotropic medium.

In a uniaxial birefringent system, n1x=n1y=n1o, and n2x=n2y=n2o.

For a biaxial birefringent system, equations 1 and 2 are valid only forlight with its plane of polarization parallel to the x-z or y-z planes,as defined in FIG. 15. So, for a biaxial system, for light incident inthe x-z plane, n1o=n1x and n2o=n2x in equation 1 (for p-polarizedlight), and n1o=n1y and n2o=n2y in equation 2 (for s-polarized light).For light incident in the y-z plane, n1o=n1y and n2o=n2y in equation 1(for p-polarized light), and n1o=n1x and n2o=n2x in equation 2 (fors-polarized light).

Equations 1 and 2 show that reflectivity depends upon the indices ofrefraction in the x, y (in-plane) and z directions of each material inthe stack. In an isotropic material, all three indices are equal, thusnx=ny=nz. The relationship between nx, ny and nz determine the opticalcharacteristics of the material. Different relationships between thethree indices lead to three general categories of materials: isotropic,uniaxially birefringent, and biaxially birefringent. Equations 1 and 2describe biaxially birefringent cases only along the x or y axis, andthen only if considered separately for the x and y directions.

A uniaxially birefringent material is defined as one in which the indexof refraction in one direction is different from the indices in theother two directions. For purposes of the present discussion, theconvention for describing uniaxially birefringent systems is for thecondition nx=ny≠nz. The x and y axes are defined as the in-plane axesand the respective indices, nx and ny, will be referred to as thein-plane indices.

One method of creating a uniaxial birefringent system is to biaxiallystretch (e.g., stretch along two dimensions) a multilayer stack in whichat least one of the materials in the stack has its index of refractionaffected by the stretching process (e.g., the index either increases ordecreases). Biaxial stretching of the multilayer stack may result indifferences between refractive indices of adjoining layers for planesparallel to both axes thus resulting in reflection of light in bothplanes of polarization.

A uniaxial birefringent material can have either positive or negativeuniaxial birefringence. Positive uniaxial birefringence occurs when thez-index is greater than the in-plane indices (nz>nx and ny). Negativeuniaxial birefringence occurs when the z-index is less than the in-planeindices (nz<nx and ny).

A biaxial birefringent material is defined as one in which the indicesof refraction in all three axes are different, e.g., nx≠ny≠nz. Again,the nx and ny indices will be referred to as the in-plane indices. Abiaxial birefringent system can be made by stretching the multilayerstack in one direction. In other words the stack is uniaxiallystretched. For purposes of the present discussion, the x direction willbe referred to as the stretch direction for biaxial birefringent stacks.

Uniaxial Birefringent Systems (Mirrors)

The optical properties and design considerations of uniaxialbirefringent systems will now be discussed. As discussed above, thegeneral conditions for a uniaxial birefringent material are nx=ny≠nz.Thus if each layer 102 and 104 in FIG. 15 is uniaxially birefringent,n1x=n1y and n2x=n2y. For purposes of the present discussion, assume thatlayer 102 has larger in-plane indices than layer 104, and that thusn1>n2 in both the x and y directions. The optical behavior of a uniaxialbirefringent multilayer system can be adjusted by varying the values ofn1z and n2z to introduce different levels of positive or negativebirefringence. The relationship between the various indices ofrefraction can be measured directly, or, the general relationship may beindirectly observed by analysis of the spectra of the resulting film asdescribed herein.

In the case of mirrors, the desired average transmission for light ofeach polarization and plane of incidence generally depends upon theintended use of the mirror. The average transmission along each stretchdirection at normal incidence for a narrow bandwidth mirror across a 100nm bandwidth within the visible spectrum is desirably less than 30%,preferably less than 20% and more preferably less than 10%. A desirableaverage transmission along each stretch direction at normal incidencefor a partial mirror ranges anywhere from, for example, 10% to 50%, andcan cover a bandwidth of anywhere between, for example, 100 nm and 450nm, depending upon the particular application. For a high efficiencymirror, average transmission along each stretch direction at normalincidence over the visible spectrum (400-700 nm) is desirably less than10%, preferably less than 5%, more preferably less than 2%, and evenmore preferably less than 1%. In addition, asymmetric mirrors may bedesirable for certain applications. In that case, average transmissionalong one stretch direction may be desirably less than, for example,50%, while the average transmission along the other stretch directionmay be desirably less than, for example 20%, over a bandwidth of, forexample, the visible spectrum (400-700 nm), or over the visible spectrumand into the near infrared (e.g, 400-850 nm).

Equation 1 described above can be used to determine the reflectivity ofa single interface in a uniaxial birefringent system composed of twolayers such as that shown in FIG. 15. Equation 2, for s polarized light,is identical to that of the case of isotropic films (nx=ny=nz), so onlyequation 1 need be examined. For purposes of illustration, somespecific, although generic, values for the film indices will beassigned. Let n1x=n1y=1.75, n1z=variable, n2x=n2y=1.50, andn2z=variable. In order to illustrate various possible Brewster angles inthis system, no=1.60 for the surrounding isotropic media.

FIG. 16 shows reflectivity versus angle curves for p-polarized lightincident from the isotropic medium to the birefringent layers, for caseswhere n1z is numerically greater than or equal to n2z (n1z≧n2z). Thecurves shown in FIG. 16 are for the following z-index values: a)n1z=1.75, n2z=1.50; b) n1z=1.75, n2z=1.57; c) n1z=1.70, n2z=1.60; d)n1z=1.65, n2z=1.60; e) n1z=1.61 , n2z=1.60; and f) n1z=1.60=n2z. As n1zapproaches n2z, the Brewster angle, the angle at which reflectivity goesto zero, increases. Curves a-e are strongly angular dependent. However,when n1z=n2z (curve f), there is no angular dependence to reflectivity.In other words, the reflectivity for curve f is constant for all anglesof incidence. At that point, equation 1 reduces to the angularindependent form: (n2o−n1o)/(n2o+n1o). When n1z=n2z, there is noBrewster effect and there is constant reflectivity for all angles ofincidence.

FIG. 17 shows reflectivity versus angle of incidence curves for caseswhere n1z is numerically less than or equal to n2z. Light is incidentfrom isotropic medium to the birefringent layers. For these cases, thereflectivity monotonically increases with angle of incidence. This isthe behavior that would be observed for s-polarized light. Curve a inFIG. 17 shows the single case for s polarized light. Curves b-e showcases for p polarized light for various values of nz, in the followingorder: b) n1z=1.50, n2z=1.60; c) n1z=1.55, n2z=1.60; d) n1z=1.59,n2z=1.60; and e) n1z=1.60=n2z. Again, when n1z=n2z (curve e), there isno Brewster effect, and there is constant reflectivity for all angles ofincidence.

FIG. 18 shows the same cases as FIGS. 16 and 17 but for an incidentmedium of index no=1.0 (air). The curves in FIG. 18 are plotted for ppolarized light at a single interface of a positive uniaxial material ofindices n2x=n2y=1.50, n2z=1.60, and a negative uniaxially birefringentmaterial with n1x=n1y=1.75, and values of n1z, in the following order,from top to bottom, of: a) 1.50; b) 1.55; c) 1.59; d) 1.60; f) 1.61; g)1.65; h) 1.70; and i) 1.75. Again, as was shown in FIGS. 16 and 17, whenthe values of n1z and n2z match (curve d), there is no angulardependence to reflectivity.

FIGS. 16, 17 and 18 show that the cross-over from one type of behaviorto another occurs when the z-axis index of one film equals the z-axisindex of the other film. This is true for several combinations ofnegative and positive uniaxially birefringent, and isotropic materials.Other situations occur in which the Brewster angle is shifted to largeror smaller angles.

Various possible relationships between in-plane indices and z-axisindices are illustrated in FIGS. 19, 20 and 21. The vertical axesindicate relative values of indices and the horizontal axes are used toseparate the various conditions. Each Figure begins at the left with twoisotropic films, where the z-index equals the in-plane indices. As oneproceeds to the right, the in-plane indices are held constant and thevarious z-axis indices increase or decrease, indicating the relativeamount of positive or negative birefringence.

The case described above with respect to FIGS. 16, 17, and 18 isillustrated in FIG. 19. The in-plane indices of material one are greaterthan the in-plane indices of material two, material 1 has negativebirefringence (n1z less than in-plane indices), and material two haspositive birefringence (n2z greater than in-plane indices). The point atwhich the Brewster angle disappears and reflectivity is constant for allangles of incidence is where the two z-axis indices are equal. Thispoint corresponds to curve f in FIG. 16, curve e in FIG. 17 or curve din FIG. 18.

In FIG. 20, material one has higher in-plane indices than material two,but material one has positive birefringence and material two hasnegative birefringence. In this case, the Brewster minimum can onlyshift to lower values of angle.

Both FIGS. 19 and 20 are valid for the limiting cases where one of thetwo films is isotropic. The two cases are where material one isisotropic and material two has positive birefringence, or material twois isotropic and material one has negative birefringence. The point atwhich there is no Brewster effect is where the z-axis index of thebirefringent material equals the index of the isotropic film.

Another case is where both films are of the same type, i.e., bothnegative or both positive birefringent. FIG. 21 shows the case whereboth films have negative birefringence. However, it shall be understoodthat the case of two positive birefringent layers is analogous to thecase of two negative birefringent layers shown in FIG. 21. As before,the Brewster minimum is eliminated only if one z-axis index equals orcrosses that of the other film.

Yet another case occurs where the in-plane indices of the two materialsare equal, but the z-axis indices differ. In this case, which is asubset of all three cases shown in FIGS. 19-21, no reflection occurs fors polarized light at any angle, and the reflectivity for p polarizedlight increases monotonically with increasing angle of incidence. Thistype of article has increasing reflectivity for p-polarized light asangle of incidence increases, and is transparent to s-polarized light.This article can be referred to as a “p-polarizer”.

The above described principles and design considerations describing thebehavior of uniaxially birefringent systems can be applied to createmultilayer stacks having the desired optical effects for a wide varietyof circumstances and applications. The indices of refraction of thelayers in the multilayer stack can be manipulated and tailored toproduce devices having the desired optical properties. Many negative andpositive uniaxial birefringent systems can be created with a variety ofin-plane and z-axis indices, and many useful devices can be designed andfabricated using the principles described here.

Biaxial Birefringent Systems (Polarizers)

Referring again to FIG. 15, two component orthogonal biaxialbirefringent systems and the design considerations affecting theresultant optical properties will now be described. Again, the systemcan have many layers, but an understanding of the optical behavior ofthe stack is achieved by examining the optical behavior at oneinterface.

A biaxial birefringent system can be designed to give high reflectivityfor light with its plane of polarization parallel to one axis, for abroad range of angles of incidence, and simultaneously have lowreflectivity and high transmission for light with its plane ofpolarization parallel to the other axis for a broad range of angles ofincidence. As a result, the biaxial birefringent system acts as apolarizer, transmitting light of one polarization and reflecting lightof the other polarization. By controlling the three indices ofrefraction of each film, nx, ny and nz, the desired polarizer behaviorcan be obtained. Again, the indices of refraction can be measureddirectly or can be indirectly observed by analysis of the spectra of theresulting film, as described herein.

Referring again to FIG. 15, the following values to the film indices areassigned for purposes of illustration: n1x=1.88, n1y=1.64, n1z=variable,n2x=1.65, n2y=variable, and n2z=variable. The x direction is referred toas the extinction direction and the y direction as the transmissiondirection.

Equation 1 can be used to predict the angular behavior of the biaxialbirefringent system for two important cases of light with a plane ofincidence in either the stretch (xz plane) or the non-stretch (yz plane)directions. The polarizer is a mirror in one polarization direction anda window in the other direction. In the stretch direction, the largeindex differential of 1.88−1.65=0.23 in a multilayer stack with hundredsof layers will yield very high reflectivities for s-polarized light. Forp-polarized light the reflectance at various angles depends on then1z/n2z index differential.

In many applications, the ideal reflecting polarizer has highreflectance along one axis (the so-called extinction axis) and zeroreflectance along the other (the so-called transmission axis), at allangles of incidence. For the transmission axis of a polarizer, itgenerally desirable to maximize transmission of light polarized in thedirection of the transmission axis over the bandwidth of interest andalso over the range of angles of interest. Average transmission atnormal incidence for a colored polarizer across a 100 nm bandwidth isdesirably at least 50%, preferably at least 70% and more preferably atleast 90%. The average transmission at 60 degrees from the normal forp-polarized light (measured along the transmission axis) for a narrowband polarizer across a 100 nm bandwidth is desirably at least 50%,preferably at least 70% and more preferably at least 80%.

The average transmission at normal incidence for a polarizer in thetransmission axis across the visible spectrum (400-700 nm for abandwidth of 300 nm) is desirably at least 50%, preferably at least 70%,more preferably at least 85%, and even more preferably at least 90%. Theaverage transmission at 60 degrees from the normal (measured along thetransmission axis) for a polarizer from 400-700 nm is desirably at least50%, preferably at least 70%, more preferably at least 80%, and evenmore preferably at least 90%.

For certain applications, high reflectivity in the transmission axis atoff-normal angles are preferred. The average reflectivity for lightpolarized along the transmission axis should be more than 20% at anangle of at least 20 degrees from the normal.

If some reflectivity occurs along the transmission axis, the efficiencyof the polarizer at off-normal angles may be reduced. If thereflectivity along the transmission axis is different for variouswavelengths, color may be introduced into the transmitted light. One wayto measure the color is to determine the root mean square (RMS) value ofthe transmissivity at a selected angle or angles over the wavelengthrange of interest. The % RMS color, C_(RMS), can be determined accordingto the equation:

$C_{RMS} = \frac{\int_{\lambda 1}^{\lambda 2}{( ( {T - \overset{\_}{T}} )^{2} )^{1/2}{\mathbb{d}\lambda}}}{\overset{\_}{T}}$where the range λ1 to λ2 is the wavelength range, or bandwidth, ofinterest, T is the transmissivity along the transmission axis, and T isthe average transmissivity along the transmission axis in the wavelengthrange of interest.

For applications where a low color polarizer is desirable, the % RMScolor should be less than 10%, preferably less than 8%, more preferablyless than 3.5%, and even more preferably less than 2.1% at an angle ofat least 30 degrees from the normal, preferably at least 45 degrees fromthe normal, and even more preferably at least 60 degrees from thenormal.

Preferably, a reflective polarizer combines the desired % RMS coloralong the transmission axis for the particular application with thedesired amount of reflectivity along the extinction axis across thebandwidth of interest. For example, for narrow band polarizers having abandwidth of approximately 100 nm, average transmission along theextinction axis at normal incidence is desirably less than 50%,preferably less than 30%, more preferably less than 10%, and even morepreferably less than 3%. For polarizers having a bandwidth in thevisible range (400-700 nm, or a bandwidth of 300 nm), averagetransmission along the extinction axis at normal incidence is desirablyless than 40%, more desirably less than 25%, preferably less than 15%,more preferably less than 5% and even more preferably less than 3%.

Reflectivity at off-normal angles, for light with its plane ofpolarization parallel to the transmission axis may be caused by a largez-index mismatch, even if the in-plane y indices are matched. Theresulting system thus has large reflectivity for p, and is highlytransparent to s polarized light. This case was referred to above in theanalysis of the mirror cases as a “p polarizer”.

For uniaxially stretched polarizers, performance depends upon therelationships between the alternating layer indices for all three (x, y,and z) directions. As described herein, it is desirable to minimize they and z index differentials for a high efficiency polarizer.Introduction of a y-index mismatch is describe to compensate for az-index mismatch. Whether intentionally added or naturally occurring,any index mismatch will introduce some reflectivity. An important factorthus is making the x-index differential larger than the y- and z-indexdifferentials. Since reflectivity increases rapidly as a function ofindex differential in both the stretch and non-stretch directions, theratios Δny/Δnx and Δnz/Δnx should be minimized to obtain a polarizerhaving high extinction along one axis across the bandwidth of interestand also over a broad range of angles, while preserving hightransmission along the orthogonal axis. Ratios of less than 0.05, 0.1 or0.25 are acceptable. Ideally, the ratio Δnz/Δnx is 0, but ratios of lessthan 0.25 or 0.5 also produce a useable polarizer.

FIG. 22 shows the reflectivity (plotted as −Log[1−R]) at 75° for ppolarized light with its plane of incidence in the non-stretchdirection, for an 800 layer stack of PEN/coPEN. The reflectivity isplotted as function of wavelength across the visible spectrum (400-700nm). The relevant indices for curve a at 550 nm are n1y=1.64, n1z=1.52,n2y=1.64 and n2z=1.63. The model stack design is a linear thicknessgrade for quarterwave pairs, where each pair thickness is given bydn=do+do(0.003)n. All layers were assigned a random thickness error witha gaussian distribution and a 5% standard deviation.

Curve a shows high off-axis reflectivity across the visible spectrumalong the transmission axis (the y-axis) and that different wavelengthsexperience different levels of reflectivity. This is due to the largez-index mismatch (Δnz=0.11). Since the spectrum is sensitive to layerthickness errors and spatial nonuniformities, such as film caliper, thisgives a biaxial birefringent system with a very nonuniform and“colorful” appearance. Although a high degree of color may be desirablefor certain applications, it is desirable to control the degree ofoff-axis color, and minimize it for those applications requiring auniform, low color appearance, such as liquid crystal displays or othertypes of displays.

Off-axis reflectivity, and off-axis color can be minimized byintroducing an index mismatch to the non-stretch in-plane indices (n1yand n2y) that create a Brewster condition off axis, while keeping thes-polarization reflectivity to a minimum.

FIG. 23 explores the effect of introducing a y-index mismatch inreducing off-axis reflectivity along the transmission axis of a biaxialbirefringent system. With n1z=1.52 and n2z=1.63 (Δnz=0.11), thefollowing conditions are plotted for p polarized light: a) n1y=n2y=1.64;b) n1y=1.64, n2y=1.62; c) n1y=1.64, n2y=1.66. Curve a shows thereflectivity where the in-plane indices n1y and n2y are equal. Curve ahas a reflectance minimum at 0°, but rises steeply after 20°. For curveb, n1y>n2y, and reflectivity increases rapidly. Curve c, where n1y<n2y,has a reflectance minimum at 38°, but rises steeply thereafter.Considerable reflection occurs as well for s polarized light forn1y≠n2y, as shown by curve d. Curves a-d of FIG. 23 indicate that thesign of the y-index mismatch (n1y−n2y) should be the same as the z-indexmismatch (n1z−n2z) for a Brewster minimum to exist. For the case ofn1y=n2y, reflectivity for s polarized light is zero at all angles.

By reducing the z-axis index difference between layers, the off axisreflectivity can be further reduced. If n1z is equal to n2z, FIG. 18indicates that the extinction axis will still have a high reflectivityoff-angle as it does at normal incidence, and no reflection would occuralong the nonstretch axis at any angle because both indices are matched(e.g., n1y=n2y and n1z=n2z).

Exact matching of the two y indices and the two z indices may not bepossible in some multilayer systems. If the z-axis indices are notmatched in a polarizer construction, introduction of a slight mismatchmay be desired for in-plane indices n1y and n2y. This can be done byblending additional components into one or both of the material layersin order to increase or decrease the respective y index as describedbelow in Example 15. Blending a second resin into either the polymerthat forms the highly birefringent layers or into the polymer that formsthe selected polymer layers may be done to modify reflection for thetransmission axis at normal and off-normal angles, or to modify theextinction of the polarizer for light polarized in the extinction axis.The second, blended resin may accomplish this by modifying thecrystallinity and the index of refraction of the polymer layers afterorientation.

Another example is plotted in FIG. 24, assuming n1z=1.56 and n2z=1.60(Δnz=0.04), with the following y indices a) n1y=1.64, n2y=1.65; b)n1y=1.64, n2y=1.63. Curve c is for s-polarized light for either case.Curve a, where the sign of the y-index mismatch is the same as thez-index mismatch, results in the lowest off-angle reflectivity.

The computed off-axis reflectance of an 800 layer stack of films at 75°angle of incidence with the conditions of curve a in FIG. 24 is plottedas curve b in FIG. 22. Comparison of curve b with curve a in FIG. 22shows that there is far less off-axis reflectivity, and therefore lowerperceived color and better uniformity, for the conditions plotted incurve b. The relevant indices for curve b at 550 nm are n1y=1.64,n1z=1.56, n2y=1.65 and n2z=1.60.

FIG. 25 shows a contour plot of equation I which summarizes the off axisreflectivity discussed in relation to FIG. 15 for p-polarized light. Thefour independent indices involved in the non-stretch direction have beenreduced to two index mismatches, Δnz and Δny. The plot is an average of6 plots at various angles of incidence from 0° to 75° in 15 degreeincrements. The reflectivity ranges from 0.4×10−4 for contour a, to4.0×10−4 for contour j, in constant increments of 0.4×10−4. The plotsindicate how high reflectivity caused by an index mismatch along oneoptic axis can be offset by a mismatch along the other axis.

Thus, by reducing the z-index mismatch between layers of a biaxialbirefringent systems, and/or by introducing a y-index mismatch toproduce a Brewster effect, off-axis reflectivity, and therefore off-axiscolor, are minimized along the transmission axis of a multilayerreflecting polarizer.

It should also be noted that narrow band polarizers operating over anarrow wavelength range can also be designed using the principlesdescribed herein. These can be made to produce polarizers in the red,green, blue, cyan, magenta, or yellow bands, for example.

An ideal reflecting polarizer should transmit all light of onepolarization, and reflect all light of the other polarization. Unlesslaminated on both sides to glass or to another film with a clear opticaladhesive, surface reflections at the air/reflecting polarizer interfacewill reduce the transmission of light of the desired polarization. Thus,it may in some cases be useful to add an antireflection (AR) coating tothe reflecting polarizer. The AR coating is preferably designed todereflect a film of index 1.64 for PEN based polarizers in air, becausethat is the index of all layers in the nonstretch (y) direction. Thesame coating will have essentially no effect on the stretch directionbecause the alternating index stack of the stretch direction has a veryhigh reflection coefficient irrespective of the presence or absence ofsurface reflections. Any AR coating known in the art could be applied,provided that the coating does not overheat or damage the multilayerfilm being coated. An exemplary coating would be a quarterwave thickcoating of low index material, ideally with index near the square rootof 1.64 (for PEN based materials).

Materials Selection and Processing

With the above-described design considerations established, one ofordinary skill will readily appreciate that a wide variety of materialscan be used to form multilayer mirrors or polarizers according to theinvention when processed under conditions selected to yield the desiredrefractive index relationships. The desired refractive indexrelationships can be achieved in a variety of ways, including stretchingduring or after film formation (e.g., in the case of organic polymers),extruding (e.g., in the case of liquid crystalline materials), orcoating. In addition, it is preferred that the two materials havesimilar rheological properties (e.g., melt viscosities) such that theycan be co-extruded.

In general, appropriate combinations may be achieved by selecting, asthe first material, a crystalline or semi-crystalline material,preferably a polymer. The second material, in turn, may be crystalline,semi-crystalline, or amorphous. The second material may have abirefringence opposite to or the same as that of the first material. Or,the second material may have no birefringence.

Specific examples of suitable materials include polyethylene naphthalate(PEN) and isomers thereof (e.g., 2,6-, 1,4-, 1,5-, 2,7-, and 2,3-PEN),polyalkylene terephthalates (e.g., polyethylene terephthalate,polybutylene terephthalate, and poly-1,4-cyclohexanedimethyleneterephthalate), polyimides (e.g., polyacrylic imides), polyetherimides,atactic polystyrene, polycarbonates, polymethacrylates (e.g.,polyisobutyl methacrylate, polypropylmethacrylate,polyethylmethacrylate, and polymethylmethacrylate), polyacrylates (e.g.,polybutylacrylate and polymethylacrylate), syndiotactic polystyrene(sPS), syndiotactic poly-alpha-methyl styrene, syndiotacticpolydichlorostyrene, copolymers and blends of any of these polystyrenes,cellulose derivatives (e.g., ethyl cellulose, cellulose acetate,cellulose propionate, cellulose acetate butyrate, and cellulosenitrate), polyalkylene polymers (e.g., polyethylene, polypropylene,polybutylene, polyisobutylene, and poly(4-methyl)pentene), fluorinatedpolymers (e.g., perfluoroalkoxy resins, polytetrafluoroethylene,fluorinated ethylene-propylene copolymers, polyvinylidene fluoride, andpolychlorotrifluoroethylene), chlorinated polymers (e.g., polyvinylidenechloride and polyvinylchloride), polysulfones, polyethersulfones,polyacrylonitrile, polyamides, silicone resins, epoxy resins,polyvinylacetate, polyether-amides, ionomeric resins, elastomers (e.g.,polybutadiene, polyisoprene, and neoprene), and polyurethanes. Alsosuitable are copolymers, e.g., copolymers of PEN (e.g., copolymers of2,6-, 1,4-, 1,5-, 2,7-, and/or 2,3-naphthalene dicarboxylic acid, oresters thereof, with (a) terephthalic acid, or esters thereof; (b)isophthalic acid, or esters thereof; (c) phthalic acid, or estersthereof; (d) alkane glycols; (e) cycloalkane glycols (e.g., cyclohexanedimethanol diol); (f) alkane dicarboxylic acids; and/or (g) cycloalkanedicarboxylic acids (e.g., cyclohexane dicarboxylic acid)), copolymers ofpolyalkylene terephthalates (e.g., copolymers of terephthalic acid, oresters thereof, with (a) naphthalene dicarboxylic acid, or estersthereof; (b) isophthalic acid, or esters thereof; (c) phthalic acid, oresters thereof, (d) alkane glycols; (e) cycloalkane glycols (e.g.,cyclohexane dimethanol diol); (f) alkane dicarboxylic acids; and/or (g)cycloalkane dicarboxylic acids (e.g., cyclohexane dicarboxylic acid)),and styrene copolymers (e.g., styrene-butadiene copolymers andstyrene-acrylonitrile copolymers), 4,4′-bibenzoic acid and ethyleneglycol. In addition, each individual layer may include blends of two ormore of the above-described polymers or copolymers (e.g., blends of SPSand atactic polystyrene). The coPEN described may also be a blend ofpellets where at least one component is a polymer based on naphthalenedicarboxylic acid and other components are other polyesters orpolycarbonates, such as a PET, a PEN or a co-PEN.

Particularly preferred combinations of layers in the case of polarizersinclude PEN/co-PEN, polyethylene terephthalate (PET)/co-PEN, PEN/sPS,PET/sPS, PEN/Eastar, and PET/Eastar, where “co-PEN” refers to acopolymer or blend based upon naphthalene dicarboxylic acid (asdescribed above) and Eastar is polycyclohexanedimethylene terephthalatecommercially available from Eastman Chemical Co.

Particularly preferred combinations of layers in the case of mirrorsinclude PET/Ecdel, PEN/Ecdel, PEN/sPS, PEN/THV, PEN/co-PET, and PET/sPS,where “co-PET” refers to a copolymer or blend based upon terephthalicacid (as described above), Ecdel is a thermoplastic polyestercommercially available from Eastman Chemical Co., and THV is afluoropolymer commercially available from 3M Co.

The number of layers in the device is selected to achieve the desiredoptical properties using the minimum number of layers for reasons offilm thickness, flexibility and economy. In the case of both polarizersand mirrors, the number of layers is preferably less than 10,000, morepreferably less than 5,000, and (even more preferably) less than 2,000.

As discussed above, the ability to achieve the desired relationshipsamong the various indices of refraction (and thus the optical propertiesof the multilayer device) is influenced by the processing conditionsused to prepare the multilayer device. In the case of organic polymerswhich can be oriented by stretching, the devices are generally preparedby co-extruding the individual polymers to form a multilayer film andthen orienting the film by stretching at a selected temperature,optionally followed by heat-setting at a selected temperature.Alternatively, the extrusion and orientation steps may be performedsimultaneously. In the case of polarizers, the film is stretchedsubstantially in one direction (uniaxial orientation), while in the caseof mirrors the film is stretched substantially in two directions(biaxial orientation).

The film may be allowed to dimensionally relax in the cross-stretchdirection from the natural reduction in cross-stretch (equal to thesquare root of the stretch ratio) to being constrained (i.e., nosubstantial change in cross-stretch dimensions). The film may bestretched in the machine direction, as with a length orienter, in widthusing a tenter.

The pre-stretch temperature, stretch temperature, stretch rate, stretchratio, heat set temperature, heat set time, heat set relaxation, andcross-stretch relaxation are selected to yield a multilayer devicehaving the desired refractive index relationship. These variables areinter-dependent; thus, for example, a relatively low stretch rate couldbe used if coupled with, e.g., a relatively low stretch temperature. Itwill be apparent to one of ordinary skill how to select the appropriatecombination of these variables to achieve the desired multilayer device.In general, however, a stretch ratios in the range from 1:2 to 1:10(more preferably 1:3 to 1:7) in the stretch direction and from 1:0.5 to1:10 (more preferably from 1:0.5 to 1:7) orthogonal to the stretchdirection is preferred.

Suitable multilayer devices may also be prepared using techniques suchas spin coating (e.g., as described in Boese et al., J. Polym. Sci.:Part B, 30:1321 (1992) for birefringent polyimides, and vacuumdeposition (e.g., as described by Zang et. al., Appl. Phys. Letters,59:823 (1991) for crystalline organic compounds; the latter technique isparticularly useful for certain combinations of crystalline organiccompounds and inorganic materials.

The invention will now be described by way of the following examples. Inthe examples, because optical absorption is negligible, reflectionequals 1 minus transmission (R=1−T).

EXAMPLE 1 Polarizer

PEN and a 70 naphthalate/30 terephthalate copolyester (coPEN) weresynthesized in a standard polyester resin kettle using ethylene glycolas the diol. The intrinsic viscosity of both the PEN and the coPEN wasapproximately 0.6 dl/g. Single layer films of PEN and coPEN wereextruded and then uniaxially stretched, with the sides restrained, atapproximately 150° C. As extruded, the PEN exhibited an isotropicrefractive index of about 1.65, and the coPEN was characterized by anisotropic refractive index of about 1.64. By isotropic is meant that therefractive indices associated with all axes in the plane of the film aresubstantially equal. Both refractive index values were observed at 550nm. After stretching at a 5:1 stretch ratio, the refractive index of thePEN associated with the oriented axis increased to approximately 1.88.The refractive index associated with the transverse axis droppedslightly to 1.64. The refractive index of the coPEN film afterstretching at a 5:1 stretch ratio remained isotropic at approximately1.64.

A satisfactory multilayer polarizer was then made of alternating layersof PEN and coPEN by coextrusion using a 51-slot feed block which fed astandard extrusion die. The extrusion was run at approximately 295° C.The PEN was extruded at approximately 23 lb/hr and the coPEN wasextruded at approximately 22.3 lb/hr. The PEN skin layers wereapproximately three times as thick as the layers within the extrudedfilm stack. All internal layers were designed to have an optical ¼wavelength thickness for light of about 1300 nm. The 51-layer stack wasextruded and cast to a thickness of approximately 0.0029 inches, andthen uniaxially stretched with the sides restrained at approximately a5:1 stretch ratio at approximately 150° C. The stretched film had athickness of approximately 0.0005 inches.

The stretched film was then heat set for 30 seconds at approximately230° C. in an air oven. The optical spectra were essentially the samefor film that was stretched and for film that was subsequently heat set.

EXAMPLE 2 Polarizer

A satisfactory 204-layered polarizer was made by extruding PEN and coPENin the 51-slot feedblock as described in Example 1 and then employingtwo layer doubling multipliers in series in the extrusion. Themultipliers divide the extruded material exiting the feed block into twohalf-width flow streams, then stack the half-width flow streams on topof each other. U.S. Pat. No. 3,565,985 describes similar coextrusionmultipliers. The extrusion was performed at approximately 295° C. usingPEN at an intrinsic viscosity of 0.50 dl/g at 22.5 lb/hr while the coPENat an intrinsic viscosity of 0.60 dl/g was run at 16.5 lb/hr. The castweb was approximately 0.0038 inches in thickness and was uniaxiallystretched at a 5:1 ratio in a longitudinal direction with the sidesrestrained at an air temperature of 140° C. during stretching. Exceptfor skin layers, all pairs of layers were designed to be ½ wavelengthoptical thickness for 550 nm light.

Two 204-layer polarizers made as described above were thenhand-laminated using an optical adhesive to produce a 408-layered filmstack. Preferably the refractive index of the adhesive should match theindex of the isotropic coPEN layer.

FIG. 5 illustrates the transmission data in both the oriented direction33 and transverse direction 31. Over 80 percent of the light in oneplane of polarization is reflected for wavelengths in a range fromapproximately 450 to 650 nm.

The iridescence is essentially a measure of nonuniformities in the filmlayers in one area versus adjacent areas. With perfect thicknesscontrol, a film stack centered at one wavelength would have no colorvariation across the sample. Multiple stacks designed to reflect theentire visible spectrum will have iridescence if significant light leaksthrough random areas at random wavelengths, due to layer thicknesserrors. The large differential index between film layers of the polymersystems presented here enable film reflectivities of greater than 99percent with a modest number of layers. This is a great advantage ineliminating iridescence if proper layer thickness control can beachieved in the extrusion process. Computer based optical modeling hasshown that greater than 99 percent reflectivity across most of thevisible spectrum is possible with only 600 layers for a PEN/coPENpolarizer if the layer thickness values are controlled with a standarddeviation of less than or equal to 10 percent.

EXAMPLE 3 PET:Ecdel, 601, Mirror

A coextruded film containing 601 layers was made on a sequentialflat-film-making line via a coextrusion process. A Polyethyleneterephthalate (PET) with an Intrinsic Viscosity of 0.6 dl/g (60 wt. %phenol/40 wt. % dichlorobenzene) was delivered by one extruder at a rateof 75 pounds per hour and Ecdel 9966 (a thermoplastic elastomeravailable from Eastman Chemical) was delivered by another extruder at arate of 65 pounds per hour. The PET was on the skin layers. Thefeedblock method (such as that described in U.S. Pat. No. 3,801,429) wasused to generate 151 layers which was passed through two multipliersproducing an extrudate of 601 layers. U.S. Pat. No. 3,565,985 describesexemplary coextrusion multipliers. The web was length oriented to a drawratio of about 3.6 with the web temperature at about 210° F. The filmwas subsequently preheated to about 235° F. in about 50 seconds anddrawn in the transverse direction to a draw ratio of about 4.0 at a rateof about 6% per second. The film was then relaxed about 5% of itsmaximum width in a heat-set oven set at 400° F. The finished filmthickness was 2.5 mil.

The cast web produced was rough in texture on the air side, and providedthe transmission as shown in FIG. 26. The % transmission for p-polarizedlight at a 60° angle (curve b) is similar the value at normal incidence(curve a) (with a wavelength shift).

For comparison, film made by Mearl Corporation, presumably of isotropicmaterials (see FIG. 27) shows a noticeable loss in reflectivity forp-polarized light at a 60° angle (curve b, compared to curve a fornormal incidence).

EXAMPLE 4 PET:Ecdel, 151, Mirror

A coextruded film containing 151 layers was made on a sequentialflat-film-making line via a coextrusion process. A Polyethyleneterephthalate (PET) with an Intrinsic Viscosity of 0.6 dl/g (60 wtphenol/40 wt. % dichlorobenzene) was delivered by one extruder at a rateof 75 pounds per hour and Ecdel 9966 (a thermoplastic elastomeravailable from Eastman Chemical) was delivered by another extruder at arate of 65 pounds per hour. The PET was on the skin layers. Thefeedblock method was used to generate 151 layers. The web was lengthoriented to a draw ratio of about 3.5 with the web temperature at about210° F. The film was subsequently preheated to about 215° F. in about 12seconds and drawn in the transverse direction to a draw ratio of about4.0 at a rate of about 25% per second. The film was then relaxed about5% of its maximum width in a heat-set oven set at 400° F. in about 6seconds. The finished film thickness was about 0.6 mil.

The transmission of this film is shown in FIG. 28. The % transmissionfor p-polarized light at a 60° angle (curve b) is similar the value atnormal incidence (curve a) with a wavelength shift. At the sameextrusion conditions the web speed was slowed down to make an infraredreflecting film with a thickness of about 0.8 mils. The transmission isshown in FIG. 29 (curve a at normal incidence, curve b at 60 degrees).

EXAMPLE 5 PEN:Ecdel, 225, Mirror

A coextruded film containing 225 layers was made by extruding the castweb in one operation and later orienting the film in a laboratoryfilm-stretching apparatus. A Polyethylene naphthalate (PEN) with anIntrinsic Viscosity of 0.5 dl/g (60 wt. % phenol/40 wt. %dichlorobenzene) was delivered by one extruder at a rate of 18 poundsper hour and Ecdel 9966 (a thermoplastic elastomer available fromEastman Chemical) was delivered by another extruder at a rate of 17pounds per hour. The PEN was on the skin layers. The feedblock methodwas used to generate 57 layers which was passed through two multipliersproducing an extrudate of 225 layers. The cast web was 12 mils thick and12 inches wide. The web was later biaxially oriented using a laboratorystretching device that uses a pantograph to grip a square section offilm and simultaneously stretch it in both directions at a uniform rate.A 7.46 cm square of web was loaded into the stretcher at about 100° C.and heated to 130° C. in 60 seconds. Stretching then commenced at100%/sec (based on original dimensions) until the sample was stretchedto about 3.5×3.5. Immediately after the stretching the sample was cooledby blowing room temperature air on it.

FIG. 30 shows the optical response of this multilayer film (curve a atnormal incidence, curve b at 60 degrees). Note that the % transmissionfor p-polarized light at a 60° angle is similar to what it is at normalincidence (with some wavelength shift).

EXAMPLE 6 PEN:THV 500, 449, Mirror

A coextruded film containing 449 layers was made by extruding the castweb in one operation and later orienting the film in a laboratoryfilm-stretching apparatus. A Polyethylene naphthalate (PEN) with anIntrinsic Viscosity of 0.53 dl/g (60 wt. % phenol/40 wt. %dichlorobenzene) was delivered by one extruder at a rate of 56 poundsper hour and THV 500 (a fluoropolymer available from Minnesota Miningand Manufacturing Company) was delivered by another extruder at a rateof 11 pounds per hour. The PEN was on the skin layers and 50% of the PENwas present in the two skin layers. The feedblock method was used togenerate 57 layers which was passed through three multipliers producingan extrudate of 449 layers. The cast web was 20 mils thick and 12 incheswide. The web was later biaxially oriented using a laboratory stretchingdevice that uses a pantograph to grip a square section of film andsimultaneously stretch it in both directions at a uniform rate. A 7.46cm square of web was loaded into the stretcher at about 100° C. andheated to 140° C. in 60 seconds. Stretching then commenced at 10%/sec(based on original dimensions) until the sample was stretched to about3.5×3.5. Immediately after the stretching the sample was cooled byblowing room temperature air at it.

FIG. 31 shows the transmission of this multilayer film. Again, curve ashows the response at normal incidence, while curve b shows the responseat 60 degrees.

EXAMPLE 7 PEN:CoPEN, 449—Low Color Polarizer

A coextruded film containing 449 layers was made by extruding the castweb in one operation and later orienting the film in a laboratoryfilm-stretching apparatus. A Polyethylene naphthalate (PEN) with anIntrinsic Viscosity of 0.56 dl/g (60 wt. % phenol/40 wt. %dichlorobenzene) was delivered by one extruder at a rate of 43 poundsper hour and a CoPEN (70 mol % 2,6 NDC and 30 mol % DMT) with anintrinsic viscosity of 0.52 (60 wt. % phenol/40 wt. % dichlorobenzene)was delivered by another extruder at a rate of 25 pounds per hour. ThePEN was on the skin layers and 40% of the PEN was present in the twoskin layers. The feedblock method was used to generate 57 layers whichwas passed through three multipliers producing an extrudate of 449layers. The cast web was 10 mils thick and 12 inches wide. The web waslater uniaxially oriented using a laboratory stretching device that usesa pantograph to grip a square section of film and stretch it in onedirection while it is constrained in the other at a uniform rate. A 7.46cm square of web was loaded into the stretcher at about 100° C. andheated to 140° C. in 60 seconds. Stretching then commenced at 10%/sec(based on original dimensions) until the sample was stretched to about5.5×1. Immediately after the stretching the sample was cooled by blowingroom temperature air at it.

FIG. 32 shows the transmission of this multilayer film. Curve a showstransmission of light polarized in the non-stretch direction at normalincidence, curve b shows transmission of p-polarized light at 60°incidence, and curve c shows transmission of light polarized in thestretch direction at normal incidence. Note the very high transmissionof light polarized in the non-stretch direction at both normal and 60°incidence. Average transmission for curve a over 400-700 nm is 87.1%,while average transmission for curve b over 400-700 nm is 97.1%.Transmission is higher for p-polarized light at 60° incidence becausethe air/PEN interface has a Brewster angle near 60°, so the transmissionat 60° incidence is nearly 100%. Also note the high extinction of lightpolarized in the stretched direction in the visible range (400-700 nm)shown by curve c, where the average transmission is 21.0%. The % RMScolor for curve a is 1.5%. The % RMS color for curve b is 1.4%.

EXAMPLE 8 PEN:CoPEN, 601—High Color Polarizer

A coextruded film containing 601 layers was produced by extruding theweb and two days later orienting the film on a different tenter thandescribed in all the other examples. A Polyethylene Naphthalate (PEN)with an Intrinsic Viscosity of 0.5 dl/g (60 wt. % phenol/40 wt. %dichlorobenzene) was delivered by one extruder at a rate of 75 poundsper hour and a CoPEN (70 mol % 2,6 NDC and 30 mol % DMT) with an IV of0.55 dl/g (60 wt. % phenol/40 wt. % dichlorobenzene) was delivered byanother extruder at a rate of 65 pounds per hour. The PEN was on theskin layers. The feedblock method was used to generate 151 layers whichwas passed through two multipliers producing an extrudate of 601 layers.U.S. Pat. No. 3,565,985 describes similar coextrusion multipliers. Allstretching was done in the tenter. The film was preheated to about 280°F. in about 20 seconds and drawn in the transverse direction to a drawratio of about 4.4 at a rate of about 6% per second. The film was thenrelaxed about 2% of its maximum width in a heat-set oven set at 460° F.The finished film thickness was 1.8 mil.

The transmission of the film is shown in FIG. 33. Curve a showstransmission of light polarized in the non-stretch direction at normalincidence, curve b shows transmission of p-polarized light at 60°incidence, and curve c shows transmission of light polarized in thestretch direction at normal incidence. Note the nonuniform transmissionof p-polarized light at both normal and 60° incidence. The averagetransmission for curve a over 400-700 nm is 84.1%, while the averagetransmission for curve b over 400-700 nm is 68.2%. The averagetransmission for curve c is 9.1%. The % RMS color for curve a is 1.4%,and the % RMS color for curve b is 11.2%.

EXAMPLE 9 PET:CoPEN, 449, Polarizer

A coextruded film containing 449 layers was made by extruding the castweb in one operation and later orienting the film in a laboratoryfilm-stretching apparatus. A Polyethylene Terephthalate (PET) with anIntrinsic Viscosity of 0.60 dl/g (60 wt. % phenol/40 wt. %dichlorobenzene) was delivered by one extruder at a rate of 26 poundsper hour and a CoPEN (70 mol % 2,6 NDC and 30 mol % DMT) with anintrinsic viscosity of 0.53 (60 wt. % phenol/40 wt. % dichlorobenzene)was delivered by another extruder at a rate of 24 pounds per hour. ThePET was on the skin layers. The feedblock method was used to generate 57layers which was passed through three multipliers producing an extrudateof 449 layers. U.S. Pat. No. 3,565,985 describes similar coextrusionmultipliers. The cast web was 7.5 mils thick and 12 inches wide. The webwas later uniaxially oriented using a laboratory stretching device thatuses a pantograph to grip a square section of film and stretch it in onedirection while it is constrained in the other at a uniform rate. A 7.46cm square of web was loaded into the stretcher at about 100° C. andheated to 120° C. in 60 seconds. Stretching then commenced at 10%/sec(based on original dimensions) until the sample was stretched to about5.0×1. Immediately after the stretching the sample was cooled by blowingroom temperature air at it. The finished film thickness was about 1.4mil. This film had sufficient adhesion to survive the orientationprocess with no delamination.

FIG. 34 shows the transmission of this multilayer film. Curve a showstransmission of light polarized in the non-stretch direction at normalincidence, curve b shows transmission of p-polarized light at 60°incidence, and curve c shows transmission of light polarized in thestretch direction at normal incidence. Note the very high transmissionof p-polarized light at both normal and 60° incidence. The averagetransmission for curve a over 400-700 nm is 88.0%, and the averagetransmission for curve b over 400-700 nm is 91.2%. The averagetransmission for curve c over 400-700 nm is 27.9%. The % RMS color forcurve a is 1.4%, and the % RMS color for curve b is 4.8%.

EXAMPLE 10 CEN:CoPEN, 601, Polarizer

A coextruded film containing 601 layers was made on a sequentialflat-film-making line via a coextrusion process. A Polyethylenenaphthalate (PEN) with an intrinsic viscosity of 0.54 dl/g (60 wt %Phenol plus 40 wt % dichlorobenzene) was delivered by on extruder at arate of 75 pounds per hour and the coPEN was delivered by anotherextruder at 65 pounds per hour. The coPEN was a copolymer of 70 mole %2,6 naphthalene dicarboxylate methyl ester, 15% dimethyl isophthalateand 15% dimethyl terephthalate with ethylene glycol. The feedblockmethod was used to generate 151 layers. The feedblock was designed toproduce a gradient distribution of layers with a ration of thickness ofthe optical layers of 1.22 for the PEN and 1.22 for the coPEN. The PENskin layers were coextruded on the outside of the optical stack with atotal thickness of 8% of the coextruded layers. The optical stack wasmultiplied by two sequential multipliers. The nominal multiplicationratio of the multipliers were 1.2 and 1.27, respectively. The film wassubsequently preheated to 310° F. in about 40 seconds and drawn in thetransverse direction to a draw ratio of about 5.0 at a rate of 6% persecond. The finished film thickness was about 2 mils.

FIG. 35 shows the transmission for this multilayer film. Curve a showstransmission of light polarized in the non-stretch direction at normalincidence, curve b shows transmission of p-polarized light at 60°incidence, and curve c shows transmission of light polarized in thestretch direction at normal incidence. Note the very high transmissionof p-polarized light at both normal and 60° incidence (80-100%). Alsonote the very high extinction of light polarized in the stretcheddirection in the visible range (400-700 nm) shown by curve c. Extinctionis nearly 100% between 500 and 650 nm.

EXAMPLE 11 PEN:sPS, 481, Polarizer

A 481 layer multilayer film was made from a polyethylene naphthalate(PEN) with an intrinsic viscosity of 0.56 dl/g measured in 60 wt. %phenol and 40 wt % dichlorobenzene purchased from Eastman Chemicals anda syndiotactic polystyrene (sPS) homopolymer (weight average molecularweight=200,000 Daltons, sampled from Dow Corporation). The PEN was onthe outer layers and was extruded at 26 pounds per hour and the sPS at23 pounds per hour. The feedblock used produced 61 layers with each ofthe 61 being approximately the same thickness. After the feedblock three(2×) multipliers were used. Equal thickness skin layers containing thesame PEN fed to the feedblock were added after the final multiplier at atotal rate of 22 pounds per hour. The web was extruded through a 12″wide die to a thickness or about 0.011 inches (0.276 mm). The extrusiontemperature was 290° C.

This web was stored at ambient conditions for nine days and thenuniaxially oriented on a tenter. The film was preheated to about 320° F.(160° C.) in about 25 seconds and drawn in the transverse direction to adraw ratio of about 6:1 at a rate of about 28% per second. No relaxationwas allowed in the stretched direction. The finished film thickness wasabout 0.0018 inches (0.046 mm).

FIG. 36 shows the optical performance of this PEN:sPS reflectivepolarizer containing 481 layers. Curve a shows transmission of lightpolarized in the non-stretch direction at normal incidence, curve bshows transmission of p-polarized light at 60° incidence, and curve cshows transmission of light polarized in the stretch direction at normalincidence. Note the very high transmission of p-polarized light at bothnormal and 60° incidence. Average transmission for curve a over 400-700nm is 86.2%, the average transmission for curve b over 400-700 nm is79.7%. Also note the very high extinction of light polarized in thestretched direction in the visible range (400-700 nm) shown by curve c.The film has an average transmission of 1.6% for curve c between 400 and700 nm. The % RMS color for curve a is 3.2%, while the % RMS color forcurve b is 18.2%.

EXAMPLE 12 PET:Ecdel, 601, Mirror

A coextruded film containing 601 layers was made on a sequentialflat-film-making line via a coextrusion process. A Polyethyleneterephthalate (PET) with an Intrinsic Viscosity of 0.6 dl/g (60 wt. %phenol/40 wt. % dichlorobenzene) was delivered to the feedblock at arate of 75 pounds per hour and Ecdel 9967 (a thermoplastic elastomeravailable from Eastman Chemical) was delivered at a rate of 60 poundsper hour. The PET was on the skin layers. The feedblock method was usedto generate 151 layers which was passed through two multipliersproducing an extrudate of 601 layers. The multipliers had a nominalmultiplication ratio of 1.2 (next to feedblock) and 1.27. Two skinlayers at a total throughput of 24 pounds per hour were addedsymmetrically between the last multiplier and the die. The skin layerswere composed of PET and were extruded by the same extruder supplyingthe PET to the feedblock. The web was length oriented to a draw ratio ofabout 3.3 with the web temperature at about 205° F. The film wassubsequently preheated to about 205° F. in about 35 seconds and drawn inthe transverse direction to a draw ratio of about 3.3 at a rate of about9% per second. The film was then relaxed about 3% of its maximum widthin a heat-set oven set at 450° F. The finished film thickness was about0.0027 inches.

The film provided the optical performance as shown in FIG. 37.Transmission is plotted as curve a and reflectivity is plotted as curveb. The luminous reflectivity for curve b is 91.5%.

EXAMPLE 13 PEN:CoPEN, 601, Antireflected Polarizer

A coextruded film containing 601 layers was made on a sequentialflat-film-making line via a coextrusion process. A Polyethylenenaphthalate (PEN) with an intrinsic viscosity of 0.54 dl/g (60 wt %Phenol plus 40 wt % dichlorobenzene) was delivered by on extruder at arate of 75 pounds per hour and the coPEN was delivered by anotherextruder at 65 pounds per hour. The coPEN was a copolymer of 70 mole %2,6 naphthalene dicarboxylate methyl ester, 30% dimethyl terephthalatewith ethylene glycol. The feedblock method was used to generate 151layers. The PEN skin layers were coextruded on the outside of theoptical stack with a total thickness of 8% of the coextruded layers. Thefeedblock was designed to make a linear gradient in layer thickness fora 149 layer optical stack with the thinnest layers on one side of thestack. The individual layer thicknesses were designed in pairs to makeequal thickness layers of the PEN and coPEN for each pair. Each pairthickness, d, was determined by the formula d=do+do*0.003*n, where do isthe minimum pair thickness, and n is the pair number between 1 and 75.The optical stack was multiplied by two sequential multipliers. Thenominal multiplication ratio of the multipliers were 1.2 and 1.27,respectively. The film was subsequently preheated to 320° F. in about 40seconds and drawn in the transverse direction to a draw ratio of about5.0 at a rate of 6% per second. The finished film thickness was about 2mils.

A silical sol gel coating was then applied to one side of the reflectingpolarizer film. The index of refraction of this coating wasapproximately 1.35. Two pieces of the AR coated reflecting polarizerfilm were cut out and the two were laminated to each other with the ARcoatings on the outside. Transmission spectra of polarized light in thecrossed and parallel directions were obtained. The sample was thenrinsed with a 2% solution of ammonium bifluoride (NH4 HF2) in deonizedwater to remove the AR coating. Spectra of the bare multilayer were thentaken for comparison to the coated sample.

FIG. 38 shows the spectra of the coated and uncoated polarizer. Curves aand b show the transmission and extinction, respectively, of the ARcoated reflecting polarizer, and curves c and d show the transmissionand extinction, respectively, of the uncoated reflecting polarizer. Notethat the extinction spectrum is essentially unchanged, but that thetransmission values for the AR coated polarizer are almost 10% higher.Peak gain was 9.9% at 565 nm, while the average gain from 425 to 700 nmwas 9.1%. Peak transmission of the AR coated polarizer was 97.0% at 675nm. Average transmissions for curve a over 400-700 nm was 95.33%, andaverage transmission for curve d over 400-700 nm was 5.42%.

EXAMPLE 14 PET:Ecdel, 601, Polarizer

A coextruded film containing 601 layers was made on a sequentialflat-film-making line via a coextrusion process. A polyethyleneterephthalate (PET) with an Intrinsic Viscosity of 0.6 dl/g (60 wt. %phenol/40 wt. % dichlorobenzene) was delivered to a feedblock by oneextruder at a rate of 75 pounds per hour and Ecdel 9967 (a thermoplasticelastomer available from Eastman Chemical) was delivered to thefeedblock by another extruder at a rate of 60 pounds per hour. The PETwas on the skin layers. The feedblock method was used to generate 151layers which passed through two multipliers (2×) producing an extrudateof 601 layers. A side stream with a throughput of 50 pounds per hour wastaken from the PET extruder and used to add two skin layers between thelast multiplier and the die. The web was length oriented to a draw ratioof about 5.0 with the web temperature at about 210° F. The film was nottentered. The finished film thickness was about 2.7 mil.

FIG. 39 shows the transmission for this film. Curve a shows thetransmission of light polarized in the stretch direction, while curve bshows the transmission of light polarized orthogonal to the stretchdirection. The average transmission from 400-700 nm for curve a is39.16%.

EXAMPLE 15 PEN:CoPEN, 449, Polarizers

A coextruded film containing 449 layers was made by extruding the castweb in one operation and later orienting the film in a laboratoryfilm-stretching apparatus. A polyethylene naphthalate (PEN) with anIntrinsic Viscosity of 0.53 dl/g (60 wt. % phenol/40 wt. %dichlorobenzene) was delivered by one extruder at a rate of 26.7 poundsper hour to the feedblock and a different material was delivered bysecond extruder at a rate of 25 pounds per hour to the feedblock. ThePEN was the skin layers. The feedblock method was used to generate 57layers which passed through three multipliers producing an extrudate of449 layers. The cast web was 0.0075 mils thick and 12 inches wide. Theweb was later uniaxially oriented using a laboratory stretching devicethat uses a pantograph to grip a square section of film and stretch itin one direction at a uniform rate while it is constrained in the other.A 7.46 cm square of web was loaded into the stretcher at about 100° C.and heated to 140° C. for 60 seconds. Stretching then commenced at10%/sec (based on original dimensions) until the sample was stretched toabout 5.5×1. Immediately after stretching, the sample was cooled byblowing room temperature air at it.

The input to the second extruder was varied by blending pellets of thefollowing poly(ethylene esters) three materials: (i) a CoPEN (70 mol %2,6-napthalene dicarboxylate and 30 mol % terephthalate) with anintrinsic viscosity of 0.52 (60 wt. % phenol/40 wt. % dichlorobenzene);(ii) the PEN, same material as input to first extruder; (iii) a PET,with an intrinsic viscosity of 0.95 (60 wt. % phenol/40 wt. %dichlorobenzene). TTF 9506 purchased from Shell.

For the film shown in FIG. 40A the input to the second extruder was 80wt % of the CoPEN and 20 wt % of the PEN; for the film shown in FIG. 40Bthe input to the second extruder was 80 wt % of the CoPEN and 20 wt % ofthe PET; for the film shown in FIG. 40C the input to the second extruderwas CoPEN.

FIGS. 40A, 40B, and 40C show the transmission of these multilayer filmswhere curve a shows transmission of light polarized in the non-stretchdirection at normal incidence, curve b shows transmission of p-polarizedlight polarized in the non-stretched direction at 60° incidence, andcurve c shows transmission of light polarized in the stretch directionat normal incidence. Note that the optical response of these films issensitive to the chemical composition of the layers from the secondextruder. The average transmission for curve c in FIG. 40A is 43.89%,the average transmission for curve c in FIG. 40B is 21.52%, and theaverage transmission for curve c in FIG. 40C is 12.48%. Thus, extinctionis increased from FIG. 40A to FIG. 40C.

For the examples using the 57 layer feedblock, all layers were designedfor only one optical thickness (¼ of 550 nm), but the extrusionequipment introduces deviations in the layer thicknesses throughout thestack resulting in a fairly broadband optical response. For examplesmade with the 151 layer feedblock, the feedblock is designed to create adistribution of layer thicknesses to cover a portion of the visiblespectrum. Asymmetric multipliers were then used to broaden thedistribution of layer thicknesses to cover most of the visible spectrumas described in U.S. Pat. Nos. 5,094,788 and 5,094,793.

The above described principles and examples regarding the opticalbehavior of multilayer films can be applied to any of the displayconfigurations shown in FIGS. 1-3, 6, 9-11 or 13. In a display such asthat shown in FIGS. 1-3, where the reflective polarizer is locatedbetween an LCD panel and an optical cavity, a high color polarizer maybe used, especially if the optical cavity produces substantiallycollimated light. The high color polarizer does not uniformly transmitlight at wide angles from the normal, which results in the nonuniformappearance and “color” off-axis. However, for those applications where acollimated light source is used, the off-axis performance of thereflective polarizer is less important.

Alternatively, in applications where a diffuser is located between thereflective polarizer and the LCD panel, a wide angle, low colorpolarizer is preferable. In this configuration, the diffuser willoperate to randomize the direction of light incident on it from thereflective polarizer. If the reflective polarizer were not low color,then some of the off-axis color generated by the reflective polarizerwould be redirected toward the normal by the diffuser. This would resultin a display with a nonuniform appearance at normal viewing angles.Thus, for a display in which a diffuser is located between thereflective polarizer and the LCD panel, a low color, wide anglereflective polarizer is preferred.

Another advantage of a low color, wide angle polarizer in the displaysshown in FIGS. 1-3 is that the undesired polarization is reflected notonly at normal angles of incidence, but also at high off-axis angles.This allows even further randomization and recycling of light to occur,thus resulting in further brightness gains for the display system.

In the displays of FIGS. 1-3, the reflective polarizer could belaminated or otherwise similarly adhered to or attached to the opticalcavity and/or to the rear of the LCD panel. Laminating the reflectivepolarizer to the optical cavity eliminates the air gap between them andthus reduces surface reflections which would otherwise occur at theair/reflective polarizer boundary. These reflection reduce the totaltransmission of the desired polarization. By attaching the reflectivepolarizer to the optical cavity, the surface reflections are reduced andtotal transmission of the desired polarization is increased.

If the reflective polarizer is not so attached to the optical cavity,use of an AR coated polarizer such as that described in Example 13 maybe desirable. The AR coated polarizer described in Example 13 was placebetween the optical cavity and the LCD panel in a backlight computerdisplay (Zenith Data Systems model Z-lite 320L). The brightness of theresulting display was measured with a Minolta brand luminance meter,model LS-100, at 90 degrees to the display surface and at a distance of1 foot. The measured brightness of the modified display was 36.9ft-lamberts. This was compared to the brightness of the unmodifieddisplay of 23.1 fl-lamberts, for a gain of 60% over the original,unmodified display. The brightness of the display using the reflectivepolarizer without the AR coating was measured at 33.7 ft-lamberts. TheAR coated reflective polarizer gave a 9.5% brighter display than did thenon-AR coated reflective polarizer.

For the display configurations shown in FIGS. 9 and 10, a brightnessenhanced reflective polarizer is placed between the LCD panel and theoptical cavity. In these configurations, a low color, wide anglereflective polarizer is preferred. This is due to the beam turningeffect of the structured surface material. The effect can be describedwith respect to FIG. 7. For a brightness enhanced reflective polarizer,light first passes through the reflective polarizing element. Thus, abeam having a large off-axis angle, such as beam 236 in FIG. 7, willpass through the reflective polarizing element and impinge upon thesmooth side of structured surface material 218. FIG. 7 shows thatstructured surface material 218 acts as a beam turning lens, redirectingbeam 236 toward the normal as it exits the structured surface side ofthe material. A low color, wide angle reflective polarizer is thereforepreferred in a display employing the brightness enhanced reflectivepolarizer because otherwise undesirable colored light is redirectedtoward the normal viewing angles of an observer. By using a low color,wide angle reflective polarizer, display uniformity at normal viewingangles is maintained.

The brightness enhanced reflective polarizer can thus benefit from theabove discussion with respect to FIGS. 23-25, and particularly FIG. 24,where off-axis color is reduced by introducing a Brewster effect at someangle away from the normal. As described above, this is achieved byintroducing a y-index mismatch between layers of the multilayerreflective polarizer, and reducing the z-index mismatch between layers.Thus, any desired combination of the brightness enhanced reflectivepolarizer can be achieved by tuning the angle of the prisms of thestructured surface material (given its respective optical behavior, suchas shown in FIGS. 7 and 8 for the 90 degree material), to the desiredoff-angle color performance of the reflective polarizer tunable throughintroduction of a y-index mismatch and reduction of the z-indexmismatch.

In the displays of FIGS. 9 and 10, the reflective polarizer could belaminated or similarly attached to the optical cavity and/or the pianoside of the structured surface material. This would provide theadvantages described above with respect to FIGS. 1-3 such as reducingsurface reflections at the air/reflective polarizer interface. If thereflective polarizer is not attached to the optical cavity, it may bedesirable to use an AR coated reflective polarizer such as thatdescribed above in Example 13.

In a display configuration such as that shown in FIG. 11, the reflectivepolarizer is located between the structured surface material and the LCDpanel. In this configuration, the restraints on the reflective polarizerare not as restrictive in terms of off-axis color. This is due to thebeam turning effects of the structured surface material. Since thestructured surface material directs light toward the normal (e.g., tendsto collimate the light) and does not transmit light at very wide angles(see FIG. 8, for example), a low color, wide angle reflective polarizeris not necessarily required in this configuration. This effect is evenmore pronounced in the display of FIG. 13, where two crossed pieces ofstructured surface material are placed behind the reflective polarizer.This results in two-dimensional collimation of light incident on thereflective polarizer.

In the case shown in FIG. 11, it is not possible to laminate thereflective polarizer to the structured side of the structured surfacematerial. In this case, is may be desirable to use an AR coatedreflective polarizer such as that described above in Example 13 toreduce surface reflections at the air/reflective polarizer interface.The AR coated polarizer described in Example 13 was placed between asheet of 90 degree structured surface material (available from MinnesotaMining and Manufacturing Company as 3M brand Optical Lighting Film) andthe backlight in a backlit computer display (Zenith Data Systems modelZ-lite 320L) to make a display configuration such as that shown in FIG.11. The grooves of the structured surface material were aligned parallelto the stretch direction of the reflective polarizer. The brightness ofthe resulting display was measured with a Minolta brand luminance meter,model LS-100, at 90 degrees to the display surface and at a distance of1 foot. The measured brightness of the modified display was 51.9ft-lamberts. This was compared to the brightness of the unmodifieddisplay of 23.1 ft-lamberts, for a gain of 125% over the original,unmodified display. The brightness of the display using the reflectivepolarizer without the AR coating was measured at 48.6 ft-lamberts. TheAR coated reflective polarizer gave a 6.8% brighter display than did thenon-AR coated reflective polarizer.

In any of the above described display configurations, the reflectivityof the reflective polarizer at a normal angle for light polarized in thetransmission axis as seen from the side facing the display backlight ispreferably less than 50%, more preferably less than 30%, more preferablyless than 20% and even more preferably less than 10%. Thesereflectivities include first surface reflection of the reflectivepolarizer. The reflectivity of the reflective polarizer for theorthogonal polarization and at a normal angle is desirably at least 50%,preferably at least 70%, more preferably at least 80%, and even morepreferably at least 90. The reflective polarizer desirably has a % RMScolor in the transmitted polarization of less than 10%, preferably lessthan 3.5%, more preferably less than 2.1%, at angles orthogonal to thepolarization of at least 30 degrees, more preferably at least 45degrees, and even more preferably at least 60 degrees.

The invention has been described with respect to illustrative examples,to which various modifications may be made without departing from thespirit and scope of the present invention as defined by the appendedclaims.

1. A display, comprising: a light source; a display module; and areflective polarizer disposed between the light source and the displaymodule and including at least one material having anisotropic refractiveindices, the reflective polarizer substantially reflecting light of afirst polarization and substantially transmitting light of a secondpolarization, wherein reflection of off-axis light of the secondpolarization exhibits a Brewster angle minimum.
 2. A display as recitedin claim 1, wherein the reflective polarizer comprises a multilayerinterference stack of different materials including the material havinganisotropic refractive indices.
 3. A display as recited in claim 2,wherein the reflective polarizer comprises alternating layers of thematerial having anisotropic indices and an isotropic material.
 4. Adisplay as recited in claim 3, wherein the index of refractiondifference between the material having anisotropic refractive indicesand the isotropic material along an axis corresponding to thepolarization state transmitted through the reflective polarizer isselected to produce the Brewster angle minimum.
 5. A display as recitedin claim 1, wherein the light source comprises at least one diffuseelement arranged to alter the polarization state of light reflected bythe reflective polarizer, the light being subsequently redirected towardthe reflective polarizer.
 6. A display, comprising: lighting means forgenerating light; modulating means for modulating light to produce animage; and polarizing means, disposed between the lighting means andmodulating means, for substantially reflecting light of a firstpolarization and substantially transmitting light of a secondpolarization, wherein polarizing means includes means for producing aBrewster angle minimum for reflection of off axis light of the secondpolarization.
 7. A display as recited in claim 6, further comprisingmeans for recycling the light of the first polarization reflected by thepolarizing means by converting a portion of such light to the secondpolarization and redirecting the light back to the polarizing means fortransmission through the polarizing means.